Could this be the start if Sluggy II?

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Re: Could this be the start if Sluggy II?

Postby Diesel Dave » Sun Aug 05, 2018 8:38 pm

One of our local bike shows is held at the Museum of Power which is an old Victorian pumping station that houses the biggest steam engine in Essex.

http://www.museumofpower.org.uk

Our local Royal Enfield club has a stand so the new bike got to be a trailer queen for the day and I got to answer the same 4 questions repeatedly.

1) Is that a Robin engine?
2) what speed will it do?
3) what MPG?
4) do you think you will ever finish it.

Still it’s good to fly the diesel flag.

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Re: Could this be the start if Sluggy II?

Postby Diesel Dave » Mon Aug 06, 2018 10:21 pm

Right, weekends over and it’s time to get back to work.

So Sluggy 2 is back on the bench and after a full days work.....spot the difference?

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No? OK so how about the other side..

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Ah yes I finally got around to rebuilding Sluggys original 5 speed gearbox so it now has a standard length mainshaft and not the extended version used for the Greaves engines.

Not the easiest of gearboxes to assemble but a lot easier than a unit Triumph version.

I has to trim a bit off the outer edge of the gearbox to engine mounting plate but now that plate can be used for either the 4 or the 5 speed gearbox.
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Re: Could this be the start if Sluggy II?

Postby Diesel Dave » Sun Aug 12, 2018 6:36 pm

Progress update.....erm, a little slow as life is getting in the way.

I had to rider longer bolts for the bottom 2 gearbox to adaptor plate positions as the 5 speeder seems to be a little wider, now arrived and fitted.

The teeny tiny radiator arrived and has been lashed into place.

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In order to get a decent plumbing run a fair amount of fiddling has been required, the top hose needed to run over the rocker cover so still uses the Axiam heater sandwich plate above the thermostat (blocked off with a dab of JB weld and a bolt).

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Super Mario plumbing required for this bit.

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And it all comes together like this

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Re: Could this be the start if Sluggy II?

Postby Diesel Dave » Wed Aug 15, 2018 3:44 am

Progress update:

I’ve been using the new bike as a test bed for fitting a disk brake to old Sluggy(1), and it was time to transfer the setup. Upon dismantling the forks I discovered several problems:-

1) left fork leg is bent
2) left damper valve circlip incorrectly fitted jamming the valve
3) right damper top nut loose inside the leg
4) progressive fork springs fitted but without the short rebound springs so over an inch of loose movement.

So it always pays to strip any ‘new’ bike and see what previous owners have bodged with.

I had some new fork legs and springs in the spares bin so it wasn’t a complete disaster,The original fork legs turned out to be thinner 350 versions so the damper valves needed a spin in the lathe to fit inside the thicker 500 type stanchions.

The upshot of all this fiddling is the Sluggy(1) now sports a disk brake; and Sluggy(2) now has straight forks supporting the original disk brake wheel.

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This problem of the bent left fork leg also answers a question that has been brooding in the back of my mind - why wasn’t there room to keep the front frame downtube intact as Steve had done in his conversion. Still the frame has been modified now and I’m happy that the front engine support is up to the task.
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Re: Could this be the start if Sluggy II?

Postby Diesel Dave » Thu Aug 30, 2018 8:27 am

Slow progress, but I keep inching forwards.


Back end reworked
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Front brake.
As I mentioned before I have never seen this type of disk brake on an Enfield, the handlebar cluster with built in master cylinder are ruined and replacements unavailable so I shall have to use a generic lever with a 10mm master cylinder bore. This left the task of rebuilding the calliper. The pistons were seized and refused to shift with either air pressure or calliper pliers so I had to use the old timer solution of replacing the bleed nipple with a grease nipple and using a grease gun to force the pistons out. It worked and the pistons were in good shape so this left the problem of finding a seal kit to rebuild with. As it turned out this was easy as the calliper is the same as a Guzzi V50.

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Back to waiting for parts to arrive...
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Re: Could this be the start if Sluggy II?

Postby gilburton » Thu Aug 30, 2018 10:18 am

Hence the rust on on the disc on your earlier pic under the tarpaulin. That is a cast iron Guzzi disc as well. Slightest drop of rain and they rust like a car disc lol
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Re: Could this be the start if Sluggy II?

Postby Diesel Dave » Thu Aug 30, 2018 12:15 pm

gilburton wrote:Hence the rust on on the disc on your earlier pic under the tarpaulin. That is a cast iron Guzzi disc as well. Slightest drop of rain and they rust like a car disc lol



At least it will work in the wet then :D

Could have been worse, one of those stainless Honda disks from the late 70’s
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Re: Could this be the start if Sluggy II?

Postby gilburton » Thu Aug 30, 2018 1:20 pm

Many years ago I had a near new 850-T3 California and sidecar. Compared with the average early Japanese braking they were light years ahead.
You pulled the brake on the jap bikes and, if it was raining,wait until the disc dried enough to actually brake lol
It might be a bit powerful on an Enfield though :shock: :lol:
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Re: Could this be the start if Sluggy II?

Postby Diesel Dave » Mon Sep 10, 2018 6:21 pm

Progress update:-

Not much to report as I’ve been in foreign lands doing the Hamm Rally (Damn good it was too).

However, whilst I was away the new Cush drive rubbers arrived so I have stripped down the rear wheel. The bearings are all good and so are the brake shoes (although they are likely to be rock hard). There was some rust inside the rim so this has been cleaned up. The worst problem was that although the wheel was quite true the spoking was loose so I spent a good half hour tensioning up the wheel and ACF50 all the spokes and nipples.

Spot the lolly stick and blu-tak!

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Today the postie delivered the long awaited front brake pipe and of course the calliper refused to bleed down so I had to resort to reverse filling with a syringe, but it has good ‘feel’ and stroke of the lever so I think it will be a good one.

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Re: Could this be the start if Sluggy II?

Postby Diesel Dave » Mon Sep 17, 2018 12:15 pm

Sometimes things don’t go my way....

I’ve been trying to work on the wiring loom so I can match together the new motor requirements to the existing loom without needing to remake the whole thing.

Sadly I’m admitting defeat, most of the loom is showing high resistance and chopping back from the connectors is showing rotten copper dissapearing back into the nether regions.

So it looks like it’s time to make a new loom - bollox.

And I’m still waiting for the alloy plates to arrive for the primary cover.
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Re: Could this be the start if Sluggy II?

Postby alexanderfoti » Mon Sep 17, 2018 5:25 pm

Just caught up on this, looks really good! Sorry for buying up all the Kubota stock :P

(although I have never bought a 2 pot kubota, plenty of 3 cylinders though). Still plodding along on my D722 superdream, but I am wanting to turbo it, starting that long journey now.

This build looks great, a turbo would set it off, I can do 67mph on the flat with my 722, the CVT is a pain though and I long for a proper gearbox. Still havent found something straight forward that would fit in the superdream frame, it is very tight!!

I have a D662 in a crate here that runs well, and has done few hours. I bought it when I thought my 722 was not going to be revived from the dead, but turns out its been fine.

I might post it up here for sale.
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