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Author Topic: The Blackhawk Cafe Project  (Read 2125 times)

High On Octane

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The Blackhawk Cafe Project
« on: May 31, 2014, 12:30:43 PM »
Well, it looks like everything is going to pan out with insurance.  I really wish I could've met with the claims adjuster yesterday but he said he would make sure to meet with me on Monday to get me a check for the insurance claim.  I'm going to be getting enough money to give the bike a full make over and replace some needed parts that have been getting neglected for awhile.  I was really pissed at this situation at first, but now it seems to be a blessing in disguise.  So far, this is what is on the agenda for the make over:

-New fork seals and springs
-New alternator & mounting bracket and rectifier
-New headlight ring and yellow H4 bulb
-New rear sets
-New Dime City "PHAT" cafe seat/fender
-New center stand and retaining spring
-New custom paint that will be even better than the first job



I'm not getting quite as much money as I had hoped for, but I'll be getting enough to replace all the major parts I need.  I still have to figure out how to afford some clip on bars and some new rear shocks too.


This is the seat pan I've decided to use as you can order it with a matching seat pad and it isn't much more than if I tried to fabricate something myself.

http://www.dimecitycycles.com/legendary-motorcycles-abs-plastic-phat-cafe-racer-motorcycle-seat-pan.html





I've also been looking at these rear shocks for awhile now and I think am going to give them a try.  The price is right and they are fully tunable.

http://www.ebay.com/itm/281163855481?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT




If everything goes to plan, I'm going to be doing a BUNCH of online shopping Monday evening.  ;D


Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

ace.cafe

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Re: The Blackhawk Cafe Project
« Reply #1 on: May 31, 2014, 12:45:18 PM »
Have fun!
 ;D

Seat looks good.
I don't know anything about the shocks. They look good.

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #2 on: May 31, 2014, 01:01:40 PM »
Have fun!
 ;D

Seat looks good.
I don't know anything about the shocks. They look good.

Thanks Tom!  BTW I have a feeling the new heads are going to be going on the Blackhawk for awhile.  You know, to make sure they are working properly.  ;D  I also have an idea for the gas tank as I won't have the money for a new one for a while.  So I was thinking of taking the original, size XXXL tank and hammering in the entire side of both sides of the tank.  This will give it a unique 1-of-a-kind look and also slim it down for more handlebar clearance.  Basically, both sides of the tank will completely dished in.  I'm then going to paint the dished parts of the tank and a stripe down the center top that will be marbleized gold paint with red pin striping.  Then on the top of the tank, on one side of the center stripe will be a small gold "Indian" logo and on the other side of the top will be a small gold "Royal Enfield" logo with my "Bulldog Kustoms" logo on the sides of the tank on the gold marbleized paint.  Tom, I also want to throw a "ACE PERFORMANCE" sticker on my paint job somewhere as well.  Can you help me out with that?

Also, Tom I'm considering converting from dual exhaust to a Y-pipe single exhaust.  I have heard that a Y-pipe (or dual exhaust with a H-pipe) helps the motor perform better with a better tuned exhaust frequency.  I have also heard that this style exhaust has better scavenging properties and can help with torque.  If I do this I think I am going to use a FMF silencer like Bullet Whisperer is using on his race bikes.  What are your thoughts on doing this?  ???

Scottie J
« Last Edit: May 31, 2014, 01:15:31 PM by High On Octane »
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

ace.cafe

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Re: The Blackhawk Cafe Project
« Reply #3 on: May 31, 2014, 01:18:43 PM »
Thanks Tom!  BTW I have a feeling the new heads are going to be going on the Blackhawk for awhile.  You know, to make sure they are working properly.  ;D  I also have an idea for the gas tank as I won't have the money for a new one for a while.  So I was thinking of taking the original, size XXXL tank and hammering in the entire side of both sides of the tank.  This will give it a unique 1-of-a-kind look and also slim it down for more handlebar clearance.  Basically, both sides of the tank will completely dished in.  I'm then going to paint the dished parts of the tank and a stripe down the center top that will be marbleized gold paint with red pin striping.  Then on the top of the tank, on one side of the center stripe will be a small gold "Indian" logo and on the other side of the top will be a small gold "Royal Enfield" logo with my "Bulldog Kustoms" logo on the sides of the tank on the gold marbleized paint.  Tom, I also want to throw a "ACE PERFORMANCE" sticker on my paint job somewhere as well.  Can you help me out with that?

Scottie J

Yes, but I'm out of stickers right now. I'll let you know when I have them.

Regarding the tank, if you look at a lot of the old racers and cafe bikes from that time period with clip-ons, they have "clearance dents" purposely formed into the forward sides of the tank, so the bars don't pinch your thumbs against the tank. You could easily hammer them in, and also hammer the rear sides in for tucking your knees in tight against the tank. Leave the area in between wide. That's the way they did it back in the day. You can look up some photos of the old cafe tanks like the Manx Sprint tank, and see examples.

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #4 on: May 31, 2014, 01:31:40 PM »
Wow, of all the pics I just looked at I think I only saw 3 or 4 bikes with that style of tank mod,  I like it!  Also, did you see I modified that last post with another question?

Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

ace.cafe

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Re: The Blackhawk Cafe Project
« Reply #5 on: May 31, 2014, 02:35:36 PM »
Wow, of all the pics I just looked at I think I only saw 3 or 4 bikes with that style of tank mod,  I like it!  Also, did you see I modified that last post with another question?

Scottie J

Yes, the Y pipe can help scavenging and power on a twin. It needs to have the right design, and since the pickings are scarce for that bike, you probably have to just hope that whoever made that siamese pipe for the twins knew what they were doing.

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #6 on: June 01, 2014, 12:53:18 PM »
Geesh.....  I don't think I've ever wanted a weekend to be over so quickly.  LOL   ;D  Not too often one actually looks forward to a Monday, eh.

Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

boggy

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Re: The Blackhawk Cafe Project
« Reply #7 on: June 02, 2014, 04:31:56 PM »
Scottie - I've seen guys make those dents by cutting out those sections, swapping the sides that they are on, and welding them back.  It requires a little bending, I'm sure.

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High On Octane

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Re: The Blackhawk Cafe Project
« Reply #8 on: June 02, 2014, 06:40:32 PM »
Scottie - I've seen guys make those dents by cutting out those sections, swapping the sides that they are on, and welding them back.  It requires a little bending, I'm sure.

Boggy

I've heard of that technique before, unfortunately I don't know how to TIG weld and that is the only way to make sure you have an air/water tight weld/seal.  I am pretty damn handy with a hammer tho.  ;)

Good news is I just received and deposited the check into my account.  Time to go shopping!!!

Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #9 on: June 03, 2014, 03:37:38 AM »
All parts are ordered except for the seat pan, rear shocks and clip ons.         ;D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #10 on: June 03, 2014, 12:54:28 PM »
Holy effing elephant crap!  I just tried leaving for work and my stupid bank froze my account again because of my purchase from Hitchcocks.  So I came home to look at things and they charged 71 GBP for shipping and handling!!!  #$@!$&^*((^$$&     >:(    Freaking crooks!   The order just ended up costing me $100 more than anticipated.  Doesn't look like I'll be ordering the seat or shocks any time soon now.   :(    After my deductible I only got $1050, the order from H's is just shy of $800 and I spent about $175 on electrical parts yesterday.  I'm pretty much tapped out.    Shit.   :-\
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

Arizoni

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Re: The Blackhawk Cafe Project
« Reply #11 on: June 03, 2014, 07:13:41 PM »
You think your pissed?

Just wait until your wife tries to buy some groceries at the store and they tell her she's broke. :(
Jim
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Re: The Blackhawk Cafe Project
« Reply #12 on: June 03, 2014, 08:14:11 PM »
Holy effing elephant crap!  I just tried leaving for work and my stupid bank froze my account again because of my purchase from Hitchcocks.  So I came home to look at things and they charged 71 GBP for shipping and handling!!!  #$@!$&^*((^$$&     >:(    Freaking crooks!   The order just ended up costing me $100 more than anticipated.  Doesn't look like I'll be ordering the seat or shocks any time soon now.   :(    After my deductible I only got $1050, the order from H's is just shy of $800 and I spent about $175 on electrical parts yesterday.  I'm pretty much tapped out.    Shit.   :-\

Thats my only hate with hitchcocks, no pre purchase shipping info :/


Also The Blackhawk Cafe would be a great cafe name... ::)
Lizzy - 07 500 Deluxe ES - Red and chrome

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #13 on: June 03, 2014, 08:48:05 PM »
You think your pissed?

Just wait until your wife tries to buy some groceries at the store and they tell her she's broke. :(

This time doesn't count.  I used insurance money.   ;D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #14 on: June 05, 2014, 12:12:45 AM »
Holy Smokes!  I ordered my alternator, Tympanium and headlight ring from The Bonneville Shop Monday night, they shipped it out yesterday morning and was in my mailbox when I got home today!  Too bad I can't install any of it until my mounting ring shows up from Hitchcocks.

Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #15 on: June 05, 2014, 04:37:30 PM »
I'm going to have find a new bank/credit union.  On top of all the BS fees they already hit me with, I discovered this morning that they are now charging me $7.89 for "international fees".  I called them and at first the guy is like "oh, we didn't charge you that visa did"  then his story changed to "well you should've been charged for those other transactions from the past but there was a glitch in the computer system".  I literally told him that they can kiss my ass and I'm not giving then any more of my hard earned money.  Why are businesses, particularity government run businesses so freaking greedy these days.  It makes me sick.

Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

ERC

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Re: The Blackhawk Cafe Project
« Reply #16 on: June 05, 2014, 04:53:16 PM »
Who did you call about the $7.89?  ERC
2-57 Apaches, 2-57 Trailblazers, 60 Chief, 65 Interceptor, 2004 Bullet, 612 Bullet chopped.

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #17 on: June 05, 2014, 05:01:23 PM »
My credit union, they are the ones who charged it.  I've never been charged before on any international orders......
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #18 on: June 07, 2014, 01:01:05 AM »
I can't believe it!  I just got home with dinner and I saw a parcel note on the table from USPS.  My parts from Hitchcocks are already here!    :o    ???   ;D

Looks like I'm going to be wrenching on the bike tomorrow.  ;D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #19 on: June 07, 2014, 02:48:09 AM »
After looking at the notice the post office left I saw that the package is marked Priority Mail Express.  I don't feel quite so bad now about spending $120 on shipping, it looks like I got my moneys worth.  3 days from England to Denver.  I have noticed that living in an international city, my packages generally arrive within 5 days time no matter where it's coming from.  :D  A lot of stuff that I buy on Ebay stateside shows up in 2-3 days from order.  Except Hitchcocks if I order without tracking.  Last 2 orders without tracking both took 2 1/2 weeks.   :-\  Anyways, I'm happy and excited to get this project rolling tomorrow!    ;D

Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #20 on: June 07, 2014, 02:40:10 PM »
Alright!  Party Time!










I grabbed my parts this morning from the post office.  Everything was there and all looks good.  I'm excited to not only have the electrical issues fixed once and for all, but I'm SUPER excited to fit these rear sets!  I've been eyeballing them for over a year and I finally had an opportunity to buy them without emptying my wallet and having to listen to wife say "Why do you spend all of your money on your bike?"  ;D

OK, I have some work to do!  Will report back later today.  Quick question tho....  The neutral finder will still work with the rear sets correct?  I would just need to remove my foot from the peg to use it, right?  I ask because I see that the rear set kit came with a neutral finder blanking kit, but I really enjoy using the neutral finder........     ???

Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

azcatfan

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Re: The Blackhawk Cafe Project
« Reply #21 on: June 07, 2014, 03:07:34 PM »
Congrats! Also, Wow, after having recently done my own alternator, that one looks puny!  I didn't realize the ES versions were so much bigger than the KS.

Have fun!
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ERC

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Re: The Blackhawk Cafe Project
« Reply #22 on: June 07, 2014, 03:27:34 PM »
I always love the way they pack them with newspaper instead of those shitty bubbles that stick to everything.  ERC
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High On Octane

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Re: The Blackhawk Cafe Project
« Reply #23 on: June 07, 2014, 08:26:39 PM »
What a PITA. Got started by removing the primary cover and discovered that the tensioner had completely removed itself and it was in fact what I was hearing/feeling clank off of the primary cover so I'm glad I didn't ride it anymore.  Problem is that when it fell out it ripped out all of the threads too so I had to get an oversized bolt (M10x1.25) a new tap and a couple of new drill bits.  Got it all to work but not without making 4 different trips and putting 25 miles on my car driving around in a 3 mile radius from my apartment.     :-\  Then I couldn't for the life of me get the alternator to line up properly even after drilling out the mounting holes.  I was seriously ready to say screw it for the day when on the last fastening of the nuts I finally got the feeler gauge to go all the way around the rotor.    :P  My back is pretty angry at me so I'm taking a short break.  Then I'll be going back out to install the rear sets.  :)

Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #24 on: June 07, 2014, 10:50:48 PM »
Why can't anything be easy?  "Install brake light switch/pedal stop bracket into the threaded hole just behind the tapered hole with the 1/2" bolt."  Yeah my frame doesn't have that threaded hole, not does the supplied brake rod fit.  I used the old brake rod but I'm going to have to do some custom fab to make a brake stop or make the new one work.    :-\
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #25 on: June 08, 2014, 12:15:53 AM »
Holy crap, my back is not happy, and I'm out of herb.  It's making it difficult to focus on this damn project when I feel like I have an elephant standing on the small of my back.    :'(

Anyways, I was able to make the brake lever stop by using the original lever stop hole and bolt and added a piece of flat metal to the bolt hole and stuck a piece of rubber hose over the metal.  Crude but functional until I can figure out what I really want to do.  I will just use the existing brake light switch for now until remedied.  Installed the right side controls too.  Turns out it is necessary to remove the neutral finder as it is in the way of the shifter linkage.  Seems like it is adjusted correctly and working as it shifts in and out of 1st gear with ease (motor not running, waiting for silicone and loctite to dry inside the primary before I fill it).  Just need to throw the exhaust back on and then all I have left is the center stand and fork springs.  But I think I will take my bike into work and do that in the shop.  I'm thinking of just wrapping some straps around the bike and hoisting it in the air with the overhead lift.  That should make it super easy to do the center stand and also make it easy to remove the front end to do the  fork springs and seals.  I'll post all of the pics once I'm completely done.  OK, going back at it again!    :D

Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #26 on: June 08, 2014, 12:19:58 AM »
OH!!!  Annnnnd  Hitchcocks totally neglects to tell you on the website or ordering process that the "cafe racer side stand is needed for the engine/frame mount bolt to fasten tightly and correctly."  I wish I had known that before I ordered, I would have ordered a new side stand instead of a center stand for the same price.  I ended up making ANOTHER trip to Ace Hardware and bought some machine bushes and cannibalized a 13mm deep socket for spacers and bushings.
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #27 on: June 08, 2014, 11:54:44 AM »
OK, here's the Pics as promised.   :)

I was about to start working on my bike in my car port when I started thinking "Man, I know this is going to be a big project and I KNOW I'm going to be making at least 1 trip to the store."  Bottom line, I didn't trust my tools just chilling around my car port for anyone to take willy nilly the second I turn my back.  So I moved my garage to the front door!  The look on my wife's face when she got home from work was priceless!  Her face said "What the hell are you doing with your motorcycle torn apart on the front door step" combined with "Well, this is shocking, yet some how doesn't surprise me."  And then when I explained why I had the bike there she actually said "Well, that makes sense.  See?!  Sometimes you just have to make the best out of what you have."  It's weird when shes nice to me while I'm working on the bike.  ;D





Next, the primary situation.  Like I said yesterday, I pulled the cover and the tensioner damn near flopped to the ground.





Mid-Chaos, this is what the wife came home too.  ;D





OH, and I removed this lovely gem from the foot rest/motor mount bar that runs underneath.  Glad they send a new 1 with the kit.





Right side rear set installed





Left rear set installed.  You can see by the arrow how I made a lever stop by taking a piece of flat metal with a piece of rubber hose around it and mounted it to the original lever stop mounting hole.





And just before the sun went down for the day.











Scottie J
« Last Edit: June 08, 2014, 11:57:02 AM by High On Octane »
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

ace.cafe

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Re: The Blackhawk Cafe Project
« Reply #28 on: June 08, 2014, 12:04:49 PM »
Looks good!

I guess the neutral finder was in the way, huh?

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #29 on: June 08, 2014, 12:12:57 PM »
Yep, it sure was.  The shift linkage rides right over the top of where the N finder goes.  Seems to shift pretty well without the motor running, and I don't believe the clutch is dragging at all now, so I should be OK.  The last few rides I was out I was figuring out the perfect technique for down shifting manually.  I had been having lots of problems before where I would go to downshift and go into a horrible loop of false neutrals where it would take several attempts to find ANY gear.  I think I finally got the clutch adjusted correctly and figured out the loving touch and pretty much eliminated that problem.  Looks like I'll be rumbling up to every stop light now instead of kicking the NF and cruising up to the light all cool and casual.   ;D

Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

ERC

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Re: The Blackhawk Cafe Project
« Reply #30 on: June 08, 2014, 12:47:17 PM »
That lever stop will be fine I did that on one I put together.  ERC
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Re: The Blackhawk Cafe Project
« Reply #31 on: June 08, 2014, 01:01:57 PM »
That lever stop will be fine I did that on one I put together.  ERC

Great minds think alike.  :)
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #32 on: June 08, 2014, 01:26:40 PM »
I'm not sure I could ride my iron barrel without the N-finder!  Nothing like coasting to a stop with the clutch lever out, I love that little lever.  Too bad you had to ditch it  :'(
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Re: The Blackhawk Cafe Project
« Reply #33 on: June 08, 2014, 01:35:56 PM »
The 5-speeds don't have it. You get used to downshifting after a while.

High On Octane

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Re: The Blackhawk Cafe Project
« Reply #34 on: June 08, 2014, 02:10:14 PM »
The 5-speeds don't have it. You get used to downshifting after a while.

I need to get used to downshifting this bike smoothly anyhow, I want to start doing some road racing.  The Auto Sports Complex I did the flat track racing at also has a paved road course that I went to start playing on.
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #35 on: June 08, 2014, 02:50:19 PM »
I still have the sloppy 4 on the left so the N-finder gets used all the time.  Down shifting isn't the problem, hitting neutral is though.  I bet the 5 speeds are much better, the RHS kit for this bike will come in time...

Nice work on the bike so far, glad you decided to keep with it  8)
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Re: The Blackhawk Cafe Project
« Reply #36 on: June 08, 2014, 04:50:29 PM »
Don't know if this might be of interest, but here's how it was done [originally] on the Bob Mcintyre Super Meteor for the 1958 Thruxton 500 miler. It took a bit of working out until I found the original R.H. exhaust pipe, then it all became clear  ;)

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Re: The Blackhawk Cafe Project
« Reply #37 on: June 08, 2014, 05:04:55 PM »
BW - I've seen that bike posted on here before.  The rear sets are definitely a different set up than Hitchcocks sells.


I took a short ride around the block and all seems well, except finding neutral.  THAT is going to take some getting used to.  lol  The bike shifts fine, but now has a completely different feel, and it feels the part.  It seriously feels like riding a 60's race bike.  Downshifting is going to take some practice as the trans is a little hard shifting to begin with and I need to get used to the angle of my feet.  Need to tighten the rear brake rod a little bit too.  Going go grab some lunch with the wife and then I'll go out for an afternoon ride and see how she's doing.  Also, leaking ATF out of the primary already and I noticed it looks like it's coming from where it mounts to the engine case.  I must not have put enough sealer on that flange to run it gasketless.  And I didn't use a gasket because I wanted to make absolutely sure that the bolt holes were fixed and not going to loosen up again.  Oh well.  I'm used to pissing anyways.   ;D

Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #38 on: June 08, 2014, 10:03:52 PM »
Went to lunch with the wife and it started raining.  Go figure.  It had slowed to a drizzle at around 2:30 so I went out for a short ride in town.  All in all the new stance is pretty comfy.  The bike shifts nice but something must be up with the clutch lever.  I get it to where the cable slack feels good but the clutch slips, I back it out and it stops slipping but then it starts to drag.  i guess I'm going to have to replace the levers after all.  I didn't have too many problems getting into neutral but there were a couple of times I had a problem.  It got stuck in 2nd at one light and I ended up stalling the bike trying to get back to 1st, luckily I got it kicked over again before the light turned red.  About 20 minutes into the ride it started to actually rain again so I just headed back home.

The only 2 issues that I see so far is that you have to raise the right foot peg to kick start or your heel will hit the peg.  And you have to raise the left foot peg to get the bike on the center stand or you will take the peg right in the shin as you try to roll in onto the stand.  Both remedied by raising the foot pegs out of the way.  A bit inconvenient but tolerable.

Also, I'm a little disappointed.  The exhaust headers are sealed tighter than a dolphins asshole now.  No more entertaining backfires out of the exhaust.   :(

Scottie J
« Last Edit: June 08, 2014, 10:17:30 PM by High On Octane »
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #39 on: June 09, 2014, 06:59:47 PM »
Rode the bike to work today and the clutch is still slipping pretty bad and also leaking ATF really bad.  I have half a mind to drain as much ATF out as possible and only leaving a splash in there.  I'm thinking this is still a residual problem from using the Advance Auto brand type F ATF, I think the plates might be glazed. 

Scottie J
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #40 on: November 23, 2014, 03:46:17 PM »
I'm bringing this thread back to life, as I believe that I have come up with a plan for my motor build, and I also have couple questions for the performance guys.

I've been speaking with a gentleman at M.A.P. Cycles, which I believe to be the leader in Brit Bike performance here in the States.  I told him my plans of building, and the fact that no one here in the US sells performance RE parts, and quite frankly, I'm tired of sending my money overseas, paying twice as much for parts, when I should be supporting the struggling economy that I live in.  After about 2 more weeks of research I have come to this conclusion:

I want steel conrods.  I'm not wasting time or money on billet aluminum rods.  I've seen too many pictures of them failing and taking out the engine.  M.A.P. Cycle makes steel H-Beams for Triumphs, BSAs and Nortons.  Upon my research, I have found that the BSA A10 conrods are damn near identical to the RE twin rods.

A10 Specs:
CtC - 6.5"
Small End Dia. - .75"
Big End Diameter - 1.8435"
Big End Width - .955

RE Specs:
CtC - 6.685" (I can't remember exactly, but this is what my memory is saying)
Small End Dia. - .75"
Big End Dia. - 1.8755"
Big End Width - .790" (measured on the crank journal).

Marino at M.A.P. believes that these will work well, and just need to have my machinist alter the big end of the rods to match the crank.  If the RE rods are in fact 6.685" (6 5/8") then using the A10 rods will actually "stroke" the motor.


Upon the recommendations of Bullet Whisperer, I will be using Triumph T120 71mm pistons.  Standard compression for the T120 is 9:1, but the dome of the piston is still 3-4 times bigger than the 8:1 RE piston.  BW recommended using the Wiseco Norman Hyde pistons, as that is what he uses, but there's an issue with this.  Even tho Wiseco is only a couple of states away from me, they will only sell those pistons directly to Norman Hyde.  So, they will more than likely cost a small fortune by the time I have them paid for and shipped.  M.A.P. Cycles sells a very nice forged piston set for $350 and appears to be very high quality.  They also happen to sell a very nice cast piston for the T120 that is only about $120 for the set with rings.  Marino says they are not as good as the forged pistons (obviously) but are "still a high quality piston, especially considering the price".

So, by going with the cast pistons and the steel rods I will only be spending about $600 for both sets.  As compared to $1200 for making custom rods or pistons, or even $1000 for H's sub-par rods and pistons.  Also, I'm going to figure out how to convert my clutch to a dry system to eliminate the slipping.  I think the only real issue that I might run into is the alternator not getting lubricated.  If it burns again, I'll just remove the charging system entirely and look into using a larger battery with a bigger reserve.

And lastly, the wheels.  I'm thinking that because I want to race this bike, and I'm not concerned with either of my bikes being completely original, that I may be better off using the fork and wheels from the Chief for the Blackhawk.  The fork is 1.25" wider than Interceptor fork that I have now, and the wheels are 16" which gives a little bit more options for performance tires.  But, I'm not sure if this will have a positive or negative effect on the handling.  If I do use the wider fork, I will have a custom billet fork brace made to help stabilize the front end.

All in all, my calculations say that I should be able to build the motor for $1800 or slightly less.  then the only other items I will need is tires, a big tach and a cafe seat which should be less than $600 for all of that.


Forged Pistons
http://www.mapcycle.com/map/index.php/categories/engine/top-end/pistons/triumph-t120-tr6-650cc-forged-pistons.html

Cast Pistons
http://www.mapcycle.com/map/index.php/categories/engine/top-end/pistons/triumph-650-1958-later-piston-set.html

4340 Steel H-Beam Rods
http://www.mapcycle.com/map/index.php/categories/engine/bottom-end/con-rods/conrod-a10-late-6-5-4340-h-beam-p-r.html
« Last Edit: November 23, 2014, 06:26:39 PM by High On Octane »
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #41 on: November 23, 2014, 06:08:25 PM »
Scottie you pasted the cast piston link twice.
2003 Classic 500 5 spd
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Re: The Blackhawk Cafe Project
« Reply #42 on: November 23, 2014, 06:27:02 PM »
Oops!  I fixed it.  :)
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #43 on: November 23, 2014, 06:46:31 PM »
Scottie if I remember correctly you will have to be careful turning the crank down if you have to cut to much the crank will be soft.  ERC
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Re: The Blackhawk Cafe Project
« Reply #44 on: November 23, 2014, 07:28:24 PM »
$200 extra doesn't seem like that much more to pay for the forged set. If you can, I would budget for this set. I see they have a T120 forged sets for $299. Why couldn't you use that set Scottie?
2003 Classic 500 5 spd
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Re: The Blackhawk Cafe Project
« Reply #45 on: November 23, 2014, 08:52:02 PM »
Changing rod length will not affect the stroke length of the engine. That can only be done by changing the crankshaft.
However, how high up the piston will come in the bore will be affected, and you will need to adjust the barrel height to suit a different rod length.

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Re: The Blackhawk Cafe Project
« Reply #46 on: November 23, 2014, 10:04:00 PM »
Scottie if I remember correctly you will have to be careful turning the crank down if you have to cut to much the crank will be soft.  ERC

The crank is only going to be turned down -.005 and then balanced and plasma-nitride treated.  I will have the rods machined to match the crank so nothing more than necessary will be removed from the crank.

$200 extra doesn't seem like that much more to pay for the forged set. If you can, I would budget for this set. I see they have a T120 forged sets for $299. Why couldn't you use that set Scottie?

I guess I had looked over that set before.  I just may end up spending the little extra for them, as you say, that is only another $200.

Changing rod length will not affect the stroke length of the engine. That can only be done by changing the crankshaft.
However, how high up the piston will come in the bore will be affected, and you will need to adjust the barrel height to suit a different rod length.

Duly noted on the stroke.  And I had taken into consideration the need to machine the barrels.  My thought was to get all the parts and have the crank done and cylinders bored and pre-assemble everything with clay on the piston tops to check to see what clearance I have and then machine or shim accordingly.
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #47 on: November 24, 2014, 10:42:43 PM »
Ace -  What lobe profiles for the cam would you recommend if I have then custom ground?
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #48 on: November 26, 2014, 06:29:29 PM »
Started reshaping the tank last night.  WAY more Bondo on the tank than what I spread on it.  Every whack of the hammer a chunk of mud just fell out.  It actually made it difficult too pound because when I'd strike it it wasn't exactly where I wanted because the Bondo was covering an already existing dent.  Should still look good when I'm done.  I think I'm going to order more metal flake and use a larger flake in conjunction with a gold pearl this time.  Should come out extra sexy.  Also, I'm going to do an "8 Ball" design on this job.  It will be a true cafe racer all said and done.



« Last Edit: November 26, 2014, 06:32:26 PM by High On Octane »
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #49 on: November 26, 2014, 06:33:35 PM »
Also, I'll have to get some clip on or clubman bars because I'm not feeling the super bike bars inverted.
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #50 on: November 26, 2014, 11:23:40 PM »
Glad to see your back working on the bike instead of selling everything.  ERC
2-57 Apaches, 2-57 Trailblazers, 60 Chief, 65 Interceptor, 2004 Bullet, 612 Bullet chopped.

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Re: The Blackhawk Cafe Project
« Reply #51 on: November 26, 2014, 11:30:36 PM »
Ace -  What lobe profiles for the cam would you recommend if I have then custom ground?

What rpm range are you targeting?
I would look at a similar thing to the R cams from the Interceptor. That seems to be a good pair. Don't over-do what the valve springs can handle. You have to consider all the stuff in the valve train.

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Re: The Blackhawk Cafe Project
« Reply #52 on: November 27, 2014, 12:22:07 AM »
What rpm range are you targeting?
I would look at a similar thing to the R cams from the Interceptor. That seems to be a good pair. Don't over-do what the valve springs can handle. You have to consider all the stuff in the valve train.
 

I'd like to shift between 6500-6800 if that is possible.

Man, my tank is looking good!   ;D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #53 on: November 27, 2014, 01:01:47 AM »
Last coat of mud, almost ready for primer!  :D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #54 on: November 27, 2014, 04:36:19 AM »
I didn't quite make it to primer.  After 4 straight hours of aggressive sanding my arms gave out and started cramping.  But, this is what it looks like so far.








I realize the sides aren't completely symmetrical but the left side was beat up really bad and it didn't shape the way I wanted it too.  The right side came out perfect tho.
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #55 on: November 27, 2014, 04:41:08 AM »
Looks great!

 I think the Interceptor R Cam type profile and a fresh set of Interceptor valve springs should work for that.

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Re: The Blackhawk Cafe Project
« Reply #56 on: November 27, 2014, 06:14:25 AM »
Ace - Doing some late night browsing and was thinking about about how Mikuni doesn't make a TM30.  So I went onto Amazon to look at the VM30 and realized I can buy TWO VM30's for $30 cheaper than I can buy ONE Amal 930.  I assume the Mikuni VM30 has got to be a better carb than the Amal 930.  Thoughts?

Also, the Interceptor valves and springs are the same as the Constellation and Super Meteor.  So I may just have to fork out a bit more for the beehive springs if we can make them them work with the stock valves.  If they are too much, I'll just order a set of new OE springs.
« Last Edit: November 27, 2014, 06:22:12 AM by High On Octane »
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #57 on: November 27, 2014, 11:33:29 AM »
Ace - Doing some late night browsing and was thinking about about how Mikuni doesn't make a TM30.  So I went onto Amazon to look at the VM30 and realized I can buy TWO VM30's for $30 cheaper than I can buy ONE Amal 930.  I assume the Mikuni VM30 has got to be a better carb than the Amal 930.  Thoughts?

Also, the Interceptor valves and springs are the same as the Constellation and Super Meteor.  So I may just have to fork out a bit more for the beehive springs if we can make them them work with the stock valves.  If they are too much, I'll just order a set of new OE springs.
VM30 carbs are fine. The disign actually was licensed from Amal originally, but I think Mikuni did a better job with it. And the Mikuni is always way cheaper than Amal. So that would be the way to go IMO.

 The beehives will not be compatible with the stock valves or stock head in that bike. Much cheaper to buy OEM. That bike should do 6500rpm+ on the stock parts. The Interceptor was rated at 6500 rpm on specs I have seen.

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Re: The Blackhawk Cafe Project
« Reply #58 on: November 27, 2014, 02:02:50 PM »
Ok great!  As long as I can easily hit 6500-6800 without running into valve bounce I think that should work just fine for now.  Besides, even new OE springs will be better than the 56 year old pieces of metal in there now, right?  ;)
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #59 on: November 27, 2014, 03:27:40 PM »
Yes, springs lose their tension/pressure with use. Newer springs have the advantage of better manufacturing, and they will be fresh. Valve springs should be changed periodically. They don't last forever.
Typically, a valve spring will lose about 10% of its pressure within the first few hours of use, and then settle in for the long haul at about 90%.
Most performance enthusiasts with high revving engines will change valve springs at least once per year. Regular motorists don'need to do that because they aren't pushing the springs to the limit.

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Re: The Blackhawk Cafe Project
« Reply #60 on: November 28, 2014, 03:37:55 AM »
Body work on the tank is finished!  Ready for high build primer and then wet sand with 500 grit paper and she'll be ready for paint.







Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #61 on: November 28, 2014, 05:08:00 PM »
I had ERC measure a conrod for me (because I don't have one handy and can't for the life of me remember how long it is).  Turns out I was wrong.  It is neither 6 3/8" NOR 6 5/8", it is 6 1/8".  But no worries to be had.  A quick search and found that the A65 and A10 have the same crank journal, only the A10 is 6.5" CtC and the A65 is 6" CtC.  So I'm still in good shape.  :D


http://www.mapcycle.com/map/index.php/categories/engine/bottom-end/con-rods/conrod-a50-a65-6-0-4340-h-beam-pr.html


Also, I just noticed that the Nikisil T120 pistons for $300 are for the Big Bore kits starting sizes at 76mm, which is way to big for my needs.  For 1 it will exceed 750cc which will put me at the bottom of the 850cc bracket for Bonneville.  Plus I don't think the cylinders can take that big of a bore.  So a No-Go on those pistons.

So I'll need to spend $350 for the full race forged pistons:
http://www.mapcycle.com/map/index.php/categories/engine/top-end/pistons/triumph-t120-tr6-650cc-forged-pistons.html
 

Or $100 on the "High Quality" cast pistons, that seriously look like a damn good piston for $100.
http://www.mapcycle.com/map/index.php/categories/engine/top-end/pistons/triumph-650-1958-later-piston-set.html

« Last Edit: November 28, 2014, 05:55:43 PM by High On Octane »
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #62 on: November 30, 2014, 01:56:01 AM »
I know when brought up before it was decided that the clip on bars from China are weak and are known to break.  I found these that are reasonably priced and seem to be a good design.  thoughts?

http://www.ebay.com/itm/Honda-Cafe-Bobber-CB450-CB500-CB750-35MM-Silver-Clipons-Clip-on-Bars-Handlebars-/200877338693?pt=Motorcycles_Parts_Accessories&hash=item2ec538f045&vxp=mtr

There are these ones as well that look even heavier duty.

http://www.ebay.com/itm/Clip-ons-35mm-black-7-8-aluminum-Vortex-clip-on-bars-cafe-racer-Triumph-BSA-/360614966971?pt=Motorcycles_Parts_Accessories&hash=item53f653b6bb&vxp=mtr
« Last Edit: November 30, 2014, 02:01:52 AM by High On Octane »
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Re: The Blackhawk Cafe Project
« Reply #63 on: December 01, 2014, 12:58:09 PM »
I just read on another blog that the US ECTA(East Coast Timing Association) LSR Speed Record Holder in 650 N/A pushrod, with his 650 Triumph twin, has dyno'd his bike at 60 hp at the engine(crank hp).
He has run somewhere around 122 mph in the flying mile on that bike, and holds the record.

Just FYI.

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Re: The Blackhawk Cafe Project
« Reply #64 on: December 01, 2014, 01:41:57 PM »
Cool, thanks for the heads up.  :)
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Re: The Blackhawk Cafe Project
« Reply #65 on: December 01, 2014, 02:32:53 PM »
Got the tank in primer this morning before I clocked in.






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Re: The Blackhawk Cafe Project
« Reply #66 on: December 01, 2014, 03:20:14 PM »
Looking very "cafe"!

 8)

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Re: The Blackhawk Cafe Project
« Reply #67 on: December 01, 2014, 05:41:05 PM »
Hope you checked it for leaks before the paint work Scottie. Great job looks good.  ERC
2-57 Apaches, 2-57 Trailblazers, 60 Chief, 65 Interceptor, 2004 Bullet, 612 Bullet chopped.

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Re: The Blackhawk Cafe Project
« Reply #68 on: December 01, 2014, 05:46:39 PM »
I didn't check for leaks with liquid but I did thoroughly inspect the tank visually for any tears or holes and and didn't see anything.  I'll be sealing the inside before final paint anyway.
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Re: The Blackhawk Cafe Project
« Reply #69 on: December 01, 2014, 06:54:23 PM »
It reminds me of the old Lyta tanks for the Gold Star Clubman DBD34.

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Re: The Blackhawk Cafe Project
« Reply #70 on: December 01, 2014, 08:13:52 PM »
All my co-workers really like it.  I'm wet sanding it in between stuff at work now.  I'm going to get it in black base and clear by end of day tomorrow.  Tom, I just heard back from my brother in law, he loves the idea of the monogram I sent you.  He is going to try and have it ready by next week.  8)
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Re: The Blackhawk Cafe Project
« Reply #71 on: December 02, 2014, 03:18:13 PM »
First stage of painting complete!!!!!   8)



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Re: The Blackhawk Cafe Project
« Reply #72 on: December 02, 2014, 06:52:58 PM »
It's purrty!
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Re: The Blackhawk Cafe Project
« Reply #73 on: December 02, 2014, 10:18:09 PM »
First stage of painting complete!!!!!   8)




Looks good what a nice job. ERC
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Re: The Blackhawk Cafe Project
« Reply #74 on: December 02, 2014, 10:26:34 PM »
Thanks Roger!  You guys thought the first paint job looked good, just wait.........   ;D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #75 on: December 03, 2014, 02:23:58 AM »
Before Pearl Coat:



After Pearl Coat:



Notice how in the shade it gets blacker as less light hits it.


I LOVE pearl coats!!!
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #76 on: December 03, 2014, 03:03:14 AM »
Me spraying the final coat of clear and a walk around of the tank.

https://www.youtube.com/watch?v=ju93mFAf6V8&feature=youtu.be
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Re: The Blackhawk Cafe Project
« Reply #77 on: December 03, 2014, 04:07:34 AM »
Oh, that is awesome Scottie!  Nice work.
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Re: The Blackhawk Cafe Project
« Reply #78 on: December 03, 2014, 03:27:35 PM »
Alright, finally finished......  For now, until I can get my custom stickers made.  :)






Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #79 on: December 03, 2014, 04:13:38 PM »
Pretty exotic looking!
What kind of pattern is on that stripe?
It sort of looks like cracked ice.

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Re: The Blackhawk Cafe Project
« Reply #80 on: December 03, 2014, 04:33:37 PM »
Pretty exotic looking!
What kind of pattern is on that stripe?
It sort of looks like cracked ice.

Thanks Ace!  The stripes I used a technique called marbelizing.  One of my favorite custom techniques, it's actually simple to do if you know how to, and looks super cool.
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #81 on: December 03, 2014, 04:37:41 PM »
Scottie please don't take this the wrong way but I think I liked your tank better all black. My opinion in this case less would have been more. I don't understand the use of the Indian and RE decals together on top of the tank and then the contrast of the gold lettering with the silver stripes and to top it off the odd color of the bar reliefs. I think you did a great job on the project. Everyone's tastes are different so you can't expect everyone to hop on board. Beauty is in the eye of the beholder (you), that is the only thing that matters. Who am I to judge, I am just a simpleton with simple ways.
« Last Edit: December 03, 2014, 05:16:19 PM by Blltrdr »
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Re: The Blackhawk Cafe Project
« Reply #82 on: December 03, 2014, 05:11:50 PM »
No offence taken, custom paint isn't for everyone.  Believe it or not, all the custom applications are all gold.  The pearl coat is gold pearl and the stripes are champagne gold base.  The original colors before the pearl are black with white pockets.  When you look at the tank in the shade, the pearl almost completely disappears.  It will look yet even different still in the sunlight.  Honestly, it was more pearl than I intended to use, but it was too late and just went with the flow.  It has actually really grown on me overnight, as it came out looking like a chameleon British Racing Green with a bronze tint to it.
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Re: The Blackhawk Cafe Project
« Reply #83 on: December 03, 2014, 05:20:19 PM »
It is just one piece of the puzzle. Will be looking forward to seeing the complete bike build.
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Re: The Blackhawk Cafe Project
« Reply #84 on: December 04, 2014, 12:08:28 AM »
Suh-weet, man!  I dig it!!

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Re: The Blackhawk Cafe Project
« Reply #85 on: December 04, 2014, 08:41:48 AM »
Nice paint job  8)
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Re: The Blackhawk Cafe Project
« Reply #86 on: December 04, 2014, 12:32:24 PM »
Thanks guys!

I am so happy with this paint job that yesterday afternoon, I sent some pics to my painting mentor back in Wisconsin.  He has been building custom Hot Rods and Street Rods for 25+ years, and the guy who taught him painted for about 40 years from the 1950's until the early 90's.  Denny has taught me pretty much everything I know, including the marblized trick I did with the stripes.  Unfortunately, he is always so busy when I do talk to him it is usually for a short time, but I had a short text conversation with him last night that I'd like to share:


Quote
Me - Hi Denny.  I wanted to show you what I've been working on.  I'm converting the Indian into a vintage 60's cafe racer and reshaped the gas tank.  It' black base with white accents on the front dimples, gold and white pearl coat and champange gold marblized stripes.  Total of 11 coats of clear.

Denny - White inserts need a couple of pale white stripes, maybe even on the marble stripes.
I can say I am very proud to say I got to teach you...  Looks really cool...  You've come a long way brother...
Looks really cool...

Me - Thanks bro!  I was thinking of doing some flat black pin stripes along the edges.  Also, inside the white is going to be getting this custom RE logo.  Up close it says RE but from a distance it looks like a vintage 8 from an 8ball.

Denny - Sweet... That will look hot.

There was more talk, but this particular part made me very happy.  When I started auto body 10 years ago, Denny told me in my first week "I will teach you what you need to know to be a good painter and body guy.  But I need YOU to commit to trying your hardest, actually listening to what I'm going to teach you, and that you stick with it and don't waste my time."  As it turns out, about 6 months later we had another conversation where he said "I'm really impressed with how far you've come.  You've been doing this for 6 months and you are already at a level of quality that takes most people 2-4 years to achieve."  That put an even bigger spark under my ass and started pushing myself.  I started coming in on Saturdays just to practice on smashed hoods and doors with old paint.  Started teaching myself to tape out graphics and flames and started playing around with candies and stuff.  I have several "test panels" I sprayed for potential projects that came out so cool I've kept them and hung them up in my garage.

What I'm getting at is that; it feels really, really good being told by the person you look up to as an inspiration that they are proud of you and what you can do and have accomplished.  This really means a lot coming from one of the best painters in the entire state of Wisconsin, likely one of the best in the entire Midwest.  :D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #87 on: December 04, 2014, 02:12:55 PM »
Ues, I think that was a great conversation with Denny.

I agree with the bordering comment.
Here's my take.
I think that the white round "meatballs" aren't perfectly round, but they are close enough that your eye can easily pick up the non-round spots. I think that a border accent of some kind which would give a more visually "perfect round" look to those white meatballs would tidy it up nicer. Mot necessarily actually being perfectly round, but giving the eye perception with the shape around the edges. If I am picking that up, then so are others. Doesn't need to be high impact contrast either. This may have been what Denny was talking about.

Just trying to give a constructive opinion about what I see.

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Re: The Blackhawk Cafe Project
« Reply #88 on: December 04, 2014, 02:35:58 PM »
Thanks Tom.  I too had noticed that about the meatballs.  All this work and its still incomplete.  Hahaha.    :D    That's why I was thinking flat black vinyl pinstripe tape along the all the edges.  Perhaps satin white would look good as well.
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Re: The Blackhawk Cafe Project
« Reply #89 on: December 04, 2014, 03:01:18 PM »
I have never seen that marbleizing effect before.
I think it is VERY trick!

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Re: The Blackhawk Cafe Project
« Reply #90 on: December 04, 2014, 06:53:27 PM »
I'm in the works of trying to acquire a sponsor today.  So far sounds promising.  Fingers Crossed!  :)
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Re: The Blackhawk Cafe Project
« Reply #91 on: December 05, 2014, 04:31:51 AM »
Thinking about installing the 16" wheels, fork and swing arm from the Chief onto the Blackhawk.  they're kind of scuzzy so I'm going to paint them.  Flat black, gloss black or gold???????
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Re: The Blackhawk Cafe Project
« Reply #92 on: December 05, 2014, 10:37:53 AM »
Flat black, gloss black or gold???????

Here's my opinion: yes.  I think you've shown us that you don't need us to choose your colors and styles for you!

Please don't design your bike by committee.  This is what happens when you do it with ferries:






Only thing I will say: dude, you gotta get a new seat cover!  ;)


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Re: The Blackhawk Cafe Project
« Reply #93 on: December 05, 2014, 11:47:13 AM »
Here's my opinion: yes.  I think you've shown us that you don't need us to choose your colors and styles for you!

Please don't design your bike by committee.  This is what happens when you do it with ferries:






Only thing I will say: dude, you gotta get a new seat cover!  ;)

Ok, point taken.   :P   As for the seat???  Hopefully I will find out more details about the "sponsor" today.  If all goes well, I will be getting a very nice aluminum cafe seat from this company.  I don't want to say anything else as not to jinx it.  ;)
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Re: The Blackhawk Cafe Project
« Reply #94 on: December 05, 2014, 04:17:49 PM »
 Sponsor Acquired!!!!!

I just found out this morning that said company will be supplying me with a custom fit, one-off prototype aluminum seat pan for cost.  Once all the details are finalized I will announce the name of the company.  But for now, my seat will look similar to this, but will be painted to match the tank.



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Re: The Blackhawk Cafe Project
« Reply #95 on: December 05, 2014, 07:21:09 PM »
Great!

What does "sponsor" mean in this case?  Will their name be blazoned across the back?  Jes' wondering...

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Re: The Blackhawk Cafe Project
« Reply #96 on: December 06, 2014, 09:39:18 PM »
Sitting here watching Ebay like a hawk....  Maybe a Blackhawk?   ;D  Anyways, I'm bidding on a sweet set of clip on bars.  Auction ends in 1hr40min, if I get them what I hope I can get them for I'll save $60 over what they normally cost.    8)
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Re: The Blackhawk Cafe Project
« Reply #97 on: December 06, 2014, 10:13:43 PM »
Great!

What does "sponsor" mean in this case?  Will their name be blazoned across the back?  Jes' wondering...

That's weird.  I replied to this yesterday but I guess it didn't post.  Anyway...

For a Joe Schmoe guy like me, getting "sponsors" is a way to promote a company while they help me out with parts and/or fuel and entry fees and such.  In my case, I'm trying get a couple of sponsors to help out with my journey to the Bonneville Salt Flats.  With this particular scenario, I found a small company that makes custom cafe racer parts, and I really liked the seat pans they had to offer.  So I emailed them saying that I has some technical questions that I'd like to speak with someone over the phone.  When I received the call from one of the owners I approached him saying "I have a small private operation, Bulldog Kustoms, and I am building a bike to race at Bonneville and also some local tracks.  I'm a kustom painter by trade, but have limited resources for custom fab.  My thought is that if you can supply me with a cafe seat pan for my bike at a substantial discount, I will be more than happy to put your companies name on my gas tank under clear coat.  Basically, one small guy to another small guy; if you scratch my back, I'll scratch your's."

He liked the idea and said that he needed to speak with his co-owner and would get back to me.  The next day I received an email saying that not only were they more than happy to help me out, but would supply me a seat pan at the cost of materials AND needed me to make a template of the seat area of the frame and take measurements and pics so they could make me a custom "unique" seat pan specifically for my bike.  I get a bad ass custom seat pan for super cheap, and they get advertisement everywhere I take my bike.  Win Win.  :D
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Re: The Blackhawk Cafe Project
« Reply #98 on: December 06, 2014, 10:59:48 PM »
Nice going Scottie. Happy for you.  ERC
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Re: The Blackhawk Cafe Project
« Reply #99 on: December 07, 2014, 02:48:21 AM »
Well I lost the auction on the Vortex clip on bars, so I started searching again and I finally came across a nice heavy duty clamp clip on that doesn't cost a fortune.  :)

http://www.ebay.com/itm/Clip-on-Handlebars-35mm-Anodized-Black-Cb450-Cb500-Cb550-Cb650-Cb750-Cl77-Gt-Gs-/281436413253?pt=Motorcycles_Parts_Accessories&hash=item4186eadd45&vxp=mtr
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Re: The Blackhawk Cafe Project
« Reply #100 on: December 09, 2014, 05:37:40 AM »
I pulled the trigger on the black clip on bars.  I contacted the seller over the phone to verify that they are made in the USA, and the y are.  He had mentioned that a couple of his local customers have them on their race bikes and really like them.  Also, he has sold several and has had no reports of breaking or failure.  Plus they have a Lifetime Warranty against defect.  What the hell, I'd rather spend $80 on something American made than $80 on some Taiwanese EMGO crap.

Also have been shopping around on Fleabay today and found a nice set of black and gold motocross shorty levers that should look and work well for this build.  Also, a nice pair of aluminum bar end mirros I've been scoping out.



http://www.ebay.com/itm/161354315548?_trksid=p2060778.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT


http://www.ebay.com/itm/321400557577?_trksid=p2060778.m1438.l2649&var=510278597990&ssPageName=STRK%3AMEBIDX%3AIT

« Last Edit: December 09, 2014, 05:40:31 AM by High On Octane »
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Re: The Blackhawk Cafe Project
« Reply #101 on: December 09, 2014, 02:35:49 PM »
Sounds good!

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Re: The Blackhawk Cafe Project
« Reply #102 on: December 09, 2014, 04:45:31 PM »
Can you mount Ace bars on the bike?

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Re: The Blackhawk Cafe Project
« Reply #103 on: December 10, 2014, 03:02:03 AM »
Can you mount Ace bars on the bike?

The Clubman bars don't look right on my bike, so that's why I'm going with clip ons.  Plus, with the clips on bars I can stretch out more with my tall body.


I started fabbing up my electrical/battery box today.  It is 5.5"x5.5"x8.5" and will house the battery and fuse panel for the custom harness I am building.  I will also be installing a key switch ignition in the front lower right corner of the box.  And on a side note.....  Sounds like I may have my sponsor's decals in the next week or two to finish the paint on the tank.  :D








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Re: The Blackhawk Cafe Project
« Reply #104 on: December 10, 2014, 03:05:40 AM »
I like the box you can hide all the electrical crap in there.  ERC
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Re: The Blackhawk Cafe Project
« Reply #105 on: December 10, 2014, 04:11:36 AM »
Ace - Can I hit 7000RPMs with big enough cams and a pair of TM32s without porting?
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Re: The Blackhawk Cafe Project
« Reply #106 on: December 10, 2014, 10:53:59 AM »
Ace - Can I hit 7000RPMs with big enough cams and a pair of TM32s without porting?
Maybe not in top gear.
The carbs would be plenty big enough, but I don't think there will be enough hp . Road tests by magazines in the 60s showed the Mk1A Interceptor to have an actual tested top speed of about 105 mph. That means it did not reach redline rpm in top gear. Hp limited.
I suppose it would depend on the cam profile you pick,  but then you could have valve spring concerns. I don't know the lift limit that is possible on the cams that can fit in the available clearance limits for that engine case. If you could fit .400" lift cams into the engine, you could get around 130 cfm flow from stock ports/valves That should get you around 51hp in hot street tune. Or maybe about 65hp in full race tune with very high compression and race gas or methanol. These are crankshaft hp estimates. Subtract about 7hp for drivetrain losses to get rwhp estimates.

IIRC, they stopped the baseline flow test at .400" lift because the upper retainer was hitting the valve guide. No more room left, and that was without a valve spring. I don't know where those springs reach coil bind. We weren't going to use them, so we just removed them. I'm guessing that you could have room for .350" lift, because that is almost what the Interceptor R cams have, and they were probably meant to use the available limits of that valve train. .350" lift would get around 125 cfm, and about 1hp less than the above figures.

These would be the expected limits, and longer cam duration may yield higher rpms to some extent if the valve train can take it, at the expense of some lower rpm torque. If you can find any performance data on the Interceptors using the R cams, you could probably expect similar results as them, using R cams.
If you are on race gas or methanol, and have around 13:1 compression, and making 53hp at the wheel, you might hit 7000 rpm in top gear, if the sprocket isn't a big one. 53 rwhp is probably good for around 122 mph. That ECTA record holding Triumph 650 that I mentioned earlier in the thread has 60 crank hp(probably about 53rwhp), and hits about 122 mph in the flying mile, naked. With a good fairing, add about 7-12 mph higher top speed, depending on how good the fairing is.
 At Bonneville, subtract 5-10 mph because of Bonneville conditions. Nobody goes as fast at Bonneville as they do at sea level on good pavement.
« Last Edit: December 10, 2014, 02:43:02 PM by ace.cafe »

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Re: The Blackhawk Cafe Project
« Reply #107 on: December 10, 2014, 11:40:55 AM »
So, here's the deal.  There is an older guy on the LandRacing.com forum who is absolutely convinced that I cannot break a record with my Enfield.  But, apparently he is willing to pay me $200 cash if I can break 135mph at Bonneville.  I did another RPM chart last night; to hit 135mph with a 22 tooth sprocket I'd need to hit 6629 RPMs, too hit 135mph with a 21 tooth sprocket I need to hit 6945 RPMs.

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Re: The Blackhawk Cafe Project
« Reply #108 on: December 10, 2014, 12:42:03 PM »
I see it as a matter of whether you can hit those rpms in top gear. This involves making enough hp at those rpms to overcome the aerodynamic drag at that speed. It's not just the simple matter of looking at a chart and thinking that 6629 rpm sounds like it should be do-able.
Regarding hitting 135 at Bonneville with stock heads, I would agree with him that you won't be able to do it.

Here's why.
Nobody else has ever been able to do it, and your build is not bringing anything out of the ordinary to the event. If it was possible to do it with stock heads and cams that fit, it would have already been done 50 years ago.
If you plan to go faster, then you require something that will get you beyond what has been done before.
« Last Edit: December 10, 2014, 12:51:04 PM by ace.cafe »

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Re: The Blackhawk Cafe Project
« Reply #109 on: December 10, 2014, 01:22:21 PM »
Ok.  Thanks.  :)
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #110 on: December 10, 2014, 01:27:58 PM »
Looks like I need just over 79hp in order to reach 135mph. 
https://www.rbracing-rsr.com/aerohpcalc.html
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #111 on: December 10, 2014, 01:43:57 PM »
Look, let's put some numbers to it.

Your stock heads with the most possible lift that the head can take, will produce 130 cfm(.400" lift). Probably they can't really do even that much without coil binding the springs. But, we'll give it the benefit of the doubt. So, with 2 heads, you are producing 260 cfm flow to work with. That is your theoretical max from these stock heads.

The hp/flow calculator estimates about 65hp max from that flow delivery, in full race "balls to the wall" methanol-burning diesel-compression level, fully cammed and fire-breathing tune. That's crankshaft hp.

It just so happens that our racing 500 Bullet heads produce flow in that general area. 260+ cfm. While we don't have data yet on exactly how fast a Bullet can go with these race heads yet, because it's "off season", we do know how fast the fastest known Bullet can go. And that is Steve Linsdell's Bullet 500. It may be still even a bit faster than ours, but we don't know yet. Anyway, with Linsdell on the bike, and world champion build and tune, with a full racing fairing with slippery aerodynamics, it has been clocked at 129.9 mph on the long straight at the Isle of Man, doing about 9000 rpm on a shortened-stroke large-bore Bullet 500.
And that is at a nearly sea level altitude on pavement. Not at 5000 feet elevation on loosely packed salt. We feel that our racing Bullet will have a good shot at being in that neighborhood, also.

135 mph does not come easy on a bike like yours. HP is expensive.
With the heads that we made for you, they lifted .500", and flowed 160 cfm per cylinder, and had valve gear to provide the full .500" lift from your available R cam lobes.
That's 320 cfm total, which the hp/flow calculator estimates 80hp in that same level of fire-breathing tune. This is about 25% more hp than your currently available most optimistic potential, and more likely almost 30% more than your more realistically attainable potential. And we are the only people in the history of the world who have ever achieved this with RE SM/Con/Inter heads.
And there, is your 135mph.

RB racing hp calculator says you need 79 hp.
The heads we made for you have potential for 80 hp.
You need a sponsor, and these heads.
« Last Edit: December 10, 2014, 02:00:36 PM by ace.cafe »

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Re: The Blackhawk Cafe Project
« Reply #112 on: December 10, 2014, 02:49:52 PM »
Ok.  Thanks as always.  I was hoping for 130mph without head work, but that obviously isn't going to happen.  Thanks for crunching the numbers.  :)
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #113 on: December 10, 2014, 03:04:44 PM »
Ok.  Thanks as always.  I was hoping for 130mph without head work, but that obviously isn't going to happen.  Thanks for crunching the numbers.  :)
Happy to do it!
 :)

Head work is the foundation of performance. Nobody wins anything on stock heads, except in classes that have restrictions for no modifications. And even they get worked over in ways that the inspectors won't notice, and that can also get expensive.

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Re: The Blackhawk Cafe Project
« Reply #114 on: December 10, 2014, 03:31:23 PM »
Did some more work to the electrical box this morning.  I'll have to wait until I get the ignition switch, kill switch and wiring before I can finish and paint it.
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #115 on: December 10, 2014, 06:56:11 PM »
How are you planning to fasten it to the frame? Hope your back is better. ERC
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Re: The Blackhawk Cafe Project
« Reply #116 on: December 10, 2014, 07:04:51 PM »
How are you planning to fasten it to the frame? Hope your back is better. ERC

The box sits flat on top on the frame.  Then I'm going to thread the 2 rear most holes/bushes that are welded into the side of the frame seat area.  That should hold it nice and tight.
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Re: The Blackhawk Cafe Project
« Reply #117 on: December 10, 2014, 10:26:16 PM »
I did that on one of mine, that way you don't screw up the frame in case somebody in the future wants an original frame for big money.  ERC
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Re: The Blackhawk Cafe Project
« Reply #118 on: December 10, 2014, 10:42:10 PM »
I did that on one of mine, that way you don't screw up the frame in case somebody in the future wants an original frame for big money.  ERC

What size tap did you use?  I was thinking 1/2x20.

My friend is coming over in a couple of hours so we can load up the Blackhawk to take it into my work to finish the build.  That way I can finish up stuff like bobbing the front fender, completing the electrical and stuff like that.  Plus when I get the seat pan everything will be ready to go for mock up and then straight to paint.  :D
« Last Edit: December 10, 2014, 10:47:00 PM by High On Octane »
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Re: The Blackhawk Cafe Project
« Reply #119 on: December 11, 2014, 01:54:35 AM »
If you're going for speed Scottie, maybe a fairing kit can help with aerodynamics?
Guys Bullet was just hitting the ton on Broadfords main straight near the end, basic avon style fairing and he said it gets up there a little quicker which makes a huge difference.
Lizzy - 07 500 Deluxe ES - Red and chrome

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Re: The Blackhawk Cafe Project
« Reply #120 on: December 11, 2014, 03:24:49 PM »
What size tap did you use?  I was thinking 1/2x20.

My friend is coming over in a couple of hours so we can load up the Blackhawk to take it into my work to finish the build.  That way I can finish up stuff like bobbing the front fender, completing the electrical and stuff like that.  Plus when I get the seat pan everything will be ready to go for mock up and then straight to paint.  :D
The bolt that comes on them is 1/2"x 26 British, the hole should already be threaded for this size.  ERC
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Re: The Blackhawk Cafe Project
« Reply #121 on: December 11, 2014, 11:04:27 PM »
Yee Haw!!!!!  Handle bars showed up today ANNNND my Christmas Visa gift card from Mom, too.  Time for more shopping!!!  Going to go pick up my wires and terminals to complete the new wire harness tonight, and then tomorrow after work I will get the new clip ons installed and run the new harness.  Then I can paint the electrical box.  After that the only thing left is head gaskets, valves springs and the new seat pan.  I'm going to have one sweet ass bike when I'm done!     :D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #122 on: December 12, 2014, 02:10:17 AM »
very interested to see what kind of terminals you use for your harness, Scottie...

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Re: The Blackhawk Cafe Project
« Reply #123 on: December 12, 2014, 03:46:27 AM »
I'm using female spade connectors for the wires going into the fuse panel, bullet connecters will be used where needed for items such as the rectifier and alternator and lights, and ring terminals for the battery connections.  I will also be adding a grounding post to the case of the electrical box.  And all the circuits are going to be color coordinated wires; green for ignition/tach, white for lighting, yellow for kill switch, black for grounds and red for the main power lead.  I will also weld 2 small L brackets to the front of the box to mount the rectifier.  Mounting it there will not only tuck it up under the seat, but will allow me to run the leads directly into the electrical box.  That way, every connection (except for lighting) will be made inside of the box, nice and tidy.  There will not be a single loose wire or connection anywhere on this bike.  No hacked wires, no redneck engineering, just nice clean black loomed wires everywhere you look.  :D

As of now, I have everything I need except for the ignition switch and kill switch, which I plan on picking up tomorrow.  Once the harness is mocked up and in place, I will do a loose wrap of electrical tape to bind the wires together and then everything will be sleeved with black romex, better known as corrugated wire looming.  After the harness is completely built and ready to rock and roll, I will strip the electrical box of everything, coat the inside with rubberized undercoating and then paint the outside of the box and lid gloss black.

Other items on the butcher block?  Chop the front fender so it is only about 14-16" long, do a little body work to get rid of the dents and then paint match it to the rest of the bike.  Tear apart the front end of the Chief and paint the triple trees gloss black, and then swap the axle and outer hubs from the 16" wheel to my 19" wheel.  This will eliminate the nacelle and my non functioning gauges.  I will eventually make a bracket that bolts to the original handlebar clamp and mount a 5" racing tach, no speedo.  Doing this will also give me the advantage of having a wider fork stance for a little better stability.

I have also been in regular contact with my sponsor.  They sent me their logos and I told them what sizes I need and they will be sending them with the seat pan.  And speaking of the seat pan, they sent me a couple of pics of the prototype seat pan design they will be using for my build.  The rear portion of this will remain the same, but the front portion will have an upward incline to follow the RE frame, similar to my generic home brewed redneck seat that is on there now.       ;D   Anyway, here is the pic.





Things are getting really exciting!!!  I've always loved my bike, but it just wasn't good enough in my eyes.  When I am done, this bike is going to win some shows.  And once I get the new motor built, it is going to win some races too!!!  Well, at least have a blast trying to win!    ;D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #124 on: December 12, 2014, 01:13:35 PM »
Here's a pic of all the goodies.   :)   Just remembered driving into work that I still need to buy some rubber grommets for where the wires go in and out of the box.  No biggie, there's an Advance close by that sells them.  ;)


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Re: The Blackhawk Cafe Project
« Reply #125 on: December 12, 2014, 02:52:34 PM »
I love the look of a wiring harness in progress.
Electrickal worries goodbye!

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Re: The Blackhawk Cafe Project
« Reply #126 on: December 12, 2014, 04:43:43 PM »
Absolutely true!  The 2 biggest complaints I constantly received about my restoration was the seat and the messy "temporary" wires.  The wiring is going to be super clean when I'm finished.  And the seat will be a one off custom, both birds killed.  LOL.  ;D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #127 on: December 12, 2014, 05:34:46 PM »
As long as that old seat cover gets killed...  ;)

Aw, c'mon, Scottie - you know we kid because we care!

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Re: The Blackhawk Cafe Project
« Reply #128 on: December 12, 2014, 06:36:24 PM »
I know Matt.  :)

Just picked up the last bits for the electrical; ignition switch, tether kill switch and a new brake light switch.


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Re: The Blackhawk Cafe Project
« Reply #129 on: December 12, 2014, 07:08:01 PM »
Looking good Scottie. Glad you didn't give up and sell everything.  ;D  ERC
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Re: The Blackhawk Cafe Project
« Reply #130 on: December 12, 2014, 08:07:37 PM »
Thanks and me too!  ;D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #131 on: December 13, 2014, 02:08:06 AM »
Big speed bump.  The electrical box hits the 18" wheel.   I have to make the box all over again and about half as wide front to back.  Damn it.  Started on the new box and stripped all the old wiring from the bike, so at least I got a little done.     :-/
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Re: The Blackhawk Cafe Project
« Reply #132 on: December 13, 2014, 11:06:44 AM »
Courage and Faith, Miss Honeychurch, Courage and Faith!

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Re: The Blackhawk Cafe Project
« Reply #133 on: December 13, 2014, 12:24:12 PM »
I'll admit I was pretty frustrated last night when I found the box didn't fit on the Blackhawk.  The only thing I can think of why it didn't fit is Because I have the Suzuki swingarm on the Chief and is almost 3" longer.  I should still be able to use it the 1st box on the Chief, so all is not lost.

One thing that does have me concerned tho is that after I removed the fender and bracket, I noticed the edge of the rear tire is rubbing against the chain guard.  I know it was always a real close fit, but I don't ever remember it making contact.  Makes me wonder if for some reason that the rear wheel came out of alignment.  Actually, now that I think of it, the last time I did a chain adjustment was in the dark.  And tho I haven't ridden a whole this year, I do remember that last few rides I took I was getting bad speed wobbles over 75mph.  Is it possible for a mis-aligned rear wheel to cause speed wobbles?  ???
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #134 on: December 13, 2014, 01:21:17 PM »
Hi Scottie,
 It looks like you are making good progress with this project. I just spotted these and wondered if they might be of any interest?
 B.W.

http://www.ebay.co.uk/itm/Royal-Enfield-Meteor-500-/261697174992?ssPageName=ADME:SS:SS:GB:1120

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Re: The Blackhawk Cafe Project
« Reply #135 on: December 13, 2014, 01:37:36 PM »
Thanks BW.  I sent the seller a message asking what stamps they have.  I have a theoretical question for you.  Could a 500 twin Meteor Minor crank be used in a 700 case and pistons to destroke the motor to a 650ish?
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #136 on: December 13, 2014, 03:38:10 PM »
The main bearings are the same. Don't know about the width on the crankcase though. If anyone knows B.W. will.  ERC
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Re: The Blackhawk Cafe Project
« Reply #137 on: December 14, 2014, 09:42:21 AM »
The main bearings are the same. Don't know about the width on the crankcase though. If anyone knows B.W. will.  ERC
One of those cranks might well fit inside the 700 cases - I don't know for sure, mind - but, if you fitted one, you would be back down to 498cc unless you plan to overbore ...
 B.W.

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Re: The Blackhawk Cafe Project
« Reply #138 on: December 14, 2014, 03:51:14 PM »
B.W. is right if you used a Meteor Minor crank, 70 x 64.5, but if it was a 500 twin crank 64 x 77 , this would make the engine almost square at 70 x 77. Not sure what capacity this would make but an interesting thought, if interceptor barrels and pistons were used it would be 71 x 77.
I have been considering the alloy one piece barrels from a mk1 Interceptor, for my Trailblazer, has anyone put interceptor barrels on a Super Meteor or Constellation ?

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Re: The Blackhawk Cafe Project
« Reply #139 on: December 14, 2014, 04:11:32 PM »
B.W. is right if you used a Meteor Minor crank, 70 x 64.5, but if it was a 500 twin crank 64 x 77 , this would make the engine almost square at 70 x 77. Not sure what capacity this would make but an interesting thought, if interceptor barrels and pistons were used it would be 71 x 77.
I have been considering the alloy one piece barrels from a mk1 Interceptor, for my Trailblazer, has anyone put interceptor barrels on a Super Meteor or Constellation ?

I have spoke with H's several times about the 1 piece alloy cylinder.  According to them, it does sit on the 700 engine case, tho the head studs need to be upgraded to 3/8" studs.  They say it will work but no one has actually done it yet.  I still wanted to do it for my build, but when I check earlier this week I saw the price increased to 588 GBP, which converts to almost $900 USD, so I won't be doing it any time soon.
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Re: The Blackhawk Cafe Project
« Reply #140 on: December 14, 2014, 06:38:50 PM »
I have spoke with H's several times about the 1 piece alloy cylinder.  According to them, it does sit on the 700 engine case, tho the head studs need to be upgraded to 3/8" studs.  They say it will work but no one has actually done it yet.  I still wanted to do it for my build, but when I check earlier this week I saw the price increased to 588 GBP, which converts to almost $900 USD, so I won't be doing it any time soon.
Thats a lot of money, But  I have a plan, I am building both engines, one quickly put together just to get it on the road and sort the teething problems out on. The second engine will be the special, I am thinking Interceptor 1 crank, alloy barrels, maybe fuel injection too.

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Re: The Blackhawk Cafe Project
« Reply #141 on: December 14, 2014, 11:07:47 PM »
Fuel injection sounds a bit complicated for an old British twin when you could get excellent results from a pair of Mikunis or even a pair of Dell'Orto PHF32 pumper carbs! B.W. also gets good results from Amal Mk2s, which would be another option. What size inlet ports do you have on the Mondello roller rocker heads?

A.
Grumpy Brit still seeking 500 AVL Bullet perfection! Will let you know if I get anywhere near...

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Re: The Blackhawk Cafe Project
« Reply #142 on: December 14, 2014, 11:27:43 PM »
Fuel injection sounds a bit complicated for an old British twin when you could get excellent results from a pair of Mikunis or even a pair of Dell'Orto PHF32 pumper carbs! B.W. also gets good results from Amal Mk2s, which would be another option. What size inlet ports do you have on the Mondello roller rocker heads?

A.
1.25" each.

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Re: The Blackhawk Cafe Project
« Reply #143 on: December 15, 2014, 08:32:16 PM »
31.75mm, that's the carb size sorted, then!

A.
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Re: The Blackhawk Cafe Project
« Reply #144 on: December 15, 2014, 09:02:01 PM »
31.75mm, that's the carb size sorted, then!

A.
Yep!
We sized them for the 32mm.
Approximate choke limit rpm is 8250 rpm for that buggy with twin 32 carbs.

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Re: The Blackhawk Cafe Project
« Reply #145 on: December 16, 2014, 03:21:03 AM »
I got some more work done on the bike today.  Round 2 of the electric box went well.  I did it slightly different than the first one and is more compact.  I'm going to have to make a different lid tho because I don't have a big enough piece of sheet metal right now to make the lid overlap the sides of the box like I want.  But there is a metal place just around the corner from work that will cut/sell any piece of metal you need in any size, so I might run down there on my lunch tomorrow.

So far this is what I have going on and got done.  The electric box is half the size of the original.  It clears the tire   ::)   and I have all the holes cut for wires and the ignition.  I installed the new rear brake light switch and also ran wire from the box to handlebars for the headlight lead and 2 wires for the kill switch.














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Re: The Blackhawk Cafe Project
« Reply #146 on: December 16, 2014, 11:25:25 PM »
Like your tank work. The whole project is taking shape really nicely.

Are your bullet-type connectors weather proof ? I like the ones used by factory on my Royal Enfield, since plastic on one side of connector overlaps the other half of connector and makes pretty strong, almost water tight fit. Bullet connectors sold by Radio Shack were not so good, as they come apart easily exposing metal parts. I guess Autozone or Advance Auto Parts have better designed products for automotive use than Radio Shack.
« Last Edit: December 16, 2014, 11:30:56 PM by singhg5 »
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Re: The Blackhawk Cafe Project
« Reply #147 on: December 17, 2014, 02:15:02 AM »
Thanks Singh!  I wanted heat shrink connectors but when I bought them I was at Home Depot and they didn't have them.  I'm not too worried about it, the only 2 connections that will not be made inside the box are the lights and 2 stator leads.  The stator leads will be loomed and the taillight I spliced in a 3 wire plug I stole off of another parts car.  I guess my bike is part Subaru now.  LOL.   ;D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #148 on: December 17, 2014, 06:03:57 AM »
Finished making my new electrical box for the Blackhawk!  The box itself is made from 1/8" plate steel and has holes cut in it for a key ignition and wires to run in and out of the box thru rubber grommets.  All connections will be made inside the box except for a couple, but they will be hidden under wire looming. The lid is made out of 16g cold roll steel, and I intentionally bent the sides a little tight so it "snaps" into place.  I will put velcro on the 2 side flanges just as a secondary measure.  I will also glue a small piece of rubber foam to the bottom side of the lid above the battery to secure the battery in place.  I built the box to have minimal clearance for the battery, so after I coat the inside with rubberized undercoating, the whole box will be insulated and have a soft cushion for the battery to rest in.  Tomorrow I will weld a short M6 stud to the inside of the electrical box for a grounding point.  The box itself will ground thru the frame at the mounting points.  Then hopefully after work tomorrow I can get the box painted and officially mount it and finish the wire harness and complete the connections inside the box.








I'm also going to weld two 6M to right side (in this pic) to mount the rectifier.



Also, I spliced in a 3 wire waterproof plug into the brake light harness.  So, any time I need to remove the brake light when I remove the exhaust, I just unplug it!   :)


Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #149 on: December 17, 2014, 06:10:15 AM »
Sweet!

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Re: The Blackhawk Cafe Project
« Reply #150 on: December 17, 2014, 01:17:34 PM »
I'm with Ace on this. Very nice.  ERC
2-57 Apaches, 2-57 Trailblazers, 60 Chief, 65 Interceptor, 2004 Bullet, 612 Bullet chopped.

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Re: The Blackhawk Cafe Project
« Reply #151 on: December 17, 2014, 10:06:35 PM »
Finally took a pic of my 2 bikes together.   :)

Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #152 on: December 17, 2014, 10:10:51 PM »
Wow! Those wheels are way different size!

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Re: The Blackhawk Cafe Project
« Reply #153 on: December 18, 2014, 12:20:25 AM »
I notice you've got your normal British oil under one.   ;D  ERC
2-57 Apaches, 2-57 Trailblazers, 60 Chief, 65 Interceptor, 2004 Bullet, 612 Bullet chopped.

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Re: The Blackhawk Cafe Project
« Reply #154 on: December 18, 2014, 12:26:01 AM »
She wanted to make herself at home.  ;D
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #155 on: December 18, 2014, 02:51:34 AM »
Alright!  Productive day today!  I got the front end disassembled on the Chief today.  Originally I was just going to paint the triple trees black, but after I stripped the paint off of the top nacelle with the wire wheel on the bench grinder, it started looking shiny.  So I decided to remove all of the casting marks with a Scothbrite 3" disc on my grinder, keeping the pad wet.  Then I wet sanded it with 500 grit, and then a quick once over with 3000 on the DA.  I didn't waste time sanding it step by step to get a mirror finish because there are a few deep gouges that can't be sanded out.  But all in all, it looks really great!  The lower stem I just painted black with the battery box after work.  Tomorrows plan is too officially finish and install the wiring, and if time permits, do the front end swap and get the new controls installed.  :D





Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #156 on: December 20, 2014, 03:43:10 PM »
The electrical is complete!   :D    Well, everything except for the headlight and killswitch, which I will do after I swap the front end out and get the new controls installed.  It didn't come out exactly how I had planned, and I may make the fused battery leads a little bit longer and try to get the plug under the fuse panel.  There are a lot of wires and plugs in a very small area and it is a little bit of a rats nest.  But once the lid is on it looks great!








Every circuit now has it's own fuse: head light, brake light, tail light, coil and ignition.




You don't know how excited I am to finally have a key for my bike!   ;D




The wiring is all nice and tidy now.  No lose wires or exposed connections and fuses.  :)




Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #157 on: December 20, 2014, 07:05:00 PM »
Ok So I've been thinking about the 500 crank again.  If I can use the 77mm stroke 500 twin crank in my 700 case and use a piston with a 73mm, that will give me 644.55cc of displacement.  That will put me in the 650cc class for Bonneville.  The record for M-650-PG is only 123.983mph.  Tom, do you think this is achievable if I have my cams ground to .360ish and get my cylinder pressure to about 200psi?
Scottie J  ~  Bulldog Kustoms Denver  ~  1958 Enfield/Indian Trailblazer  ~  1959 Enfield/Indian Chief

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Re: The Blackhawk Cafe Project
« Reply #158 on: Today at 01:44:55 PM »
Your really moving it along Scottie,looking really good.  ERC
2-57 Apaches, 2-57 Trailblazers, 60 Chief, 65 Interceptor, 2004 Bullet, 612 Bullet chopped.