Free time = work time

I cleaned and painted the front foot pegs. I had some rubber for them from another motorcycle and it fitted perfect. The pegs are not original for this motorcycle but they will do until i find original ones. The axis that hold the pegs broke while i was stress testing it (i weigh 96kg) so i had to manufacture a new one.IMG_0653

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The sidecar rear support came back from the metal manufacturer and it fits ok.

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The left rubber grip on the steering bar is from another movie, so another part that is “temporary” until i find better ones.

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I installed seals and gaskets for the exhaust and when i tried to fasten the nuts i realised that one of the front exhaust sections did not have the correct angle. It took about an hour with the help of a friend, a gas torch, and a metall pipe to get that basterd in.

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Another work day

I found some pvc pipe that fitted ok on the carburators so i will use it for the air intakes until i make some better ones from textolite.

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I installed the exhaust but without any seals. I have some fiber glass sheets that i’ll transform into exhaust seals in a couple of days (to read: as soon as i find them)

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I managed to make some more scratches to the paint while installing the back sit support, but nothing i can’t patch up.

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IMG_0651The rubber sit i used is from an M i think so i have to buy a new one.

 

The gas tank.

Time to install the gas tank. I didn’t remember where to place the MZ emblem so i temporary placed it where it “looked” ok. Also installed the knee protectors. Everything went smooth, no real problems here. Getting the cables under the gas tank was a little more tricky, considering the cables are a little two short. I had to extend them a little so they would fit ok inside the headlight, so at least a coule of hours were spent to fix cutting the two short 😀

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Tool box and generator

Fixed up some of the electrics, i have spark so i managed to keep everything intact.

The “tool box” is complete, i just have to seal a couple of unused holes, add a battery strip and a screw to keep the fuse pannel in place.

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* Just noticed the next morning that i also added a couple of scratches to ….everything. Not very big so i hope i can fill/polish them.

The generator is also in place, and it seems to be working ok, i have a nice strong spark, and everything fell into place without too much trouble.

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All that’s left of the electrical part of the job is to strap the main cables to the frame, add the back light, mount the brake sensor, and the sidecar plug.

Little things that take time

One of the parts i forgot to remove from one of the frames and paint was the upper sidecar connection mount. And it seems it has a mind of it’s own as it took me about an hour, half of AB-80 spray, a flame torch and a BIG hammer to take it out.

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Another 30 minutes of cleaning the rust and waiting for the primer to dry and i had this:

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Working on this reminded me of the missing rear sidecar mounting piece. I need to fabricate that one tomorrow, as i have two from an IJ56 probably, that need a little grinding and a new screw thread.

 

Fork and front lights done.

Finished the front fork today. Not my best work, as you can still hear some unhealthy metal sounds from it, and will need at least new bushes if not one of this sets full of goodies: http://www.motorradmeistermilz.de/Telegabel-Fuehrungsrohre-Komplett-mit-Buchsen-Faltenbaelge-und-Schellen-IFA-MZ-BK-350

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Overall it performs ok, i need to test it more when i get the engine running, however except for the strange noise made by the home made bushes everything seems ok. I don’t have any strange movements anymore and everything is stable.

I fixed the back fender support so it now aligns ok on the wheel. I will have to repaint this tomorrow as i fucked up the paint but i least everything falls nicely into place.

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And the last thing i managed to do before the cold got to me was finish the headlight. I had to make a locking support from inside the headlight from aluminium foil, i run out of zink foil. I will have to see if the aluminium resists the vibrations from the road.

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Headlight in 30 minutes.

Just got back in town and i found an hour to tingle with the motorcycle. I managed to mount the headlight, align the glass nicely and sealed it in place, added LED lights for the “charging” and “neutral” lights so the little plastic covers no longer heet up and crack, modified the back of the speed indicator so i can fit a light inside (the modell i found was not identical on the back side to the original) and sealed it on the headlight. All i have left to do is insert the rubber seal for the speedometer cable and i’m done with this.

– insert headlight photo –

I also managed to mount the light switch to the clutch lever. Mine used to mount to the handle bar however the clutch lever was not for this modell so a little improvisation had to be made. Now it looks almost like the original modell, so i don’t know if to keep this or look for the original ones.

– insert light switch photo –

Are we there yet?

Tool box aligned up nicely, also did the front fork. Slight problems with the front fender, that basterd is difficult to insert in the fork without any scratches on it.
Unfortunately old problem with the front fork is back in action. The complete assembly is week, i can move the steering bar a couple of degrees while holding the front wheel in place. I don’t know why this happens but i think it’s related to how tight everything is. I will retighten everything as soon as i get the chance.

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And a last moment photo with the tank and driver sit, just to see how it looks.

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It looks good =))

I have to buy new tires, the ugly ones i have on right now are made in Ucraine and i think are for Dneper. They are very hard and too wide and will definitely  touch the supports of the fenders if i compress the springs too much.

I have to go out of town for a couple of days so i have to sort the rest of the issues next week