hi i'm paul brodie you might have heard of me i make stuff there's a guy behind the camera
you might have heard of him too his name is mitch in between the two of us we make
these videos and we show you the process of creating thanks for hanging out in the shop here
we're going to work on the cub today i'm going to show you what's new there's a few things that new
there's a little bit of bad news but when you work on a project not everything can go
perfectly i know that you probably know that too i got the head worked on so look it's got brand
new valve guides see those and and they're bronze i think the stock ones are made out of cast iron
and and the seats are cut the valves have been lapped in so it's going to go together soon so
we're working on all these different things so that pretty soon hopefully we can assemble the
motor today we're going to work on the flywheels but we're going to do a little bit of what's new
first as well here's the seat base that i started working on and i've got the basically the shape
done there's been quite a bit of bondo work in there filling in the low spots and that
so you can see how it fits what the seat base does it defines the shape of the bottom of the seat
and that's kind of crucial because that's part of the look of the bike
so it defines the bottom and it also it defines the shape that the seat comes out of
obviously it doesn't go straight up but it's going to come up and round and
so that's it okay when i i made it it was not a perfect ark this side was too wide it was kind of
an odd shape so i used cardboard and i traced it so i put some bondo inside and then i can
grind it down and make it smaller so now it's the same shape around like that and what i want
to show you is while i was i was fiberglassing this i had a plastic sheet over here it wasn't
actual plastic it was a plastic drop sheet for painting and look what happened here
i didn't get any fiberglass on it but the fumes affected the paint so that's more work for me
now i have to sand it and and touch it up i don't want to take it all apart so anyway that's what
happens when you work on a project sometimes things go well and sometimes they don't i owned
a cub in high school when i was 15 years old and i bought it off a friend in high school he was 15 as
well it was the first time that he'd worked on a motorcycle and he bought the cub as a basket case
after i bought it off him several weeks later or whatever he told me that when he assembled
the flywheels he used a two pound hammer and he basically beat them together which is just
horrendous so what we're gonna do here is to take apart this set of flywheels
i think this one's probably okay it's got it's got some side play i can't really feel
well actually maybe there's a little bit of up and down play not huge so what i have here
i've got a brand new rod assembly and when you first look at it you think what what is that
but this is a coating which is put on at the factory let's just peel it off and see what's
underneath it oh there's a little a little bit of rust but that's okay that'll polish up but so this
is the coating this is brand new this is probably 55 years old so we're going to take off all this
probably wash it in some solvent yeah let's just open this up a little bit and see what's going on
should be brand new bearings and everything in there
i guess these might be hard there you go there's a bearing there's the needle bearing
and that's just surface rust on this side surface rust so that'll polish off so we're going to take
this over to the press we're going to press it apart but first i think what i want to show you is
i've got these v blocks this is what i made for the aramaki flywheels and it's the right spacing
for an aramaki but you can see here it's it's a little bit too wide but we can still turn it
and i'm i'm going to set up i've got this all set up so if i set that to zero there
oh look at that it's out 11th hour about that's that side let's check the other side here
i looked in the hanes manual and the hanes manual says that the maximum it can be out
is two thousand so okay i got a key way here so i'm not gonna put it onto the keyway
it's gonna go right beside the keyway so we're at zero we turn it round
and so this side is out what three thousand four thousand like that so it's not straight
oh here we go
so the next thing to do is to wash these parts but first i'm going to use some really
fine fine wet and dry paper and take all the rust off here so we'll go back to lathe and
do that in the wonderful hanes manual it shows you how to take a pot a flywheel you
just saw how i took it apart what they want you to do is to have a tool or make a tool
and then you just crank it down well that might work i guess if you got nothing else
i guess it could work but it's nicer to have a press just very smooth operation
okay so that took off the rust that looks good so what i'm concerned about now is the sharp
edge there so that's why i set up the grinder like this i got the rubber wheel on there so
so even though it's a rubber wheel you saw that you saw the sparks so
that's not as sharp anymore so that's good when this goes in i need to line up
this hole with that so that's about where that's going to go like that so we'll just
go wash everything make sure everything's clean and we'll and we'll blow it all out and then we'll
assemble soon if i plug that see how it comes out the middle that shows pretty good flow okay
i've taken electrical tape and i've i've wound the tape around it's plugged up the three holes so now
when i put the salt you can see it coming out now can't you
okay we're good okay so that's what we're gonna do now
this goes in that has to line up with that oil oil gallery there
don't put much on there it just helps it to slide just a little bit better
actually mitch had a good idea and that was to use the vice and we can we can get it going in
the vise because it'll it'll center itself a little bit so let's just see what happens yeah
okay now we'll use the press
make sure we've got some oil to start with here
oh look there's almost no side play at all that's a nice fit
okay so you can see that this has been used on other flywheels here
this is a chunk of aluminum probably 6061 and i've got a lead hammer here so
if i put one of the flywheel halves on top of this aluminum block
then i hit the other one and they should shift so can you see what's happening here can you see that
this is high and it it hinges around on the crank pin so we're going to give it a little tap
just a little tap
that's a little tap
okay so it didn't move it because that's about the same it's easy to move now because it's only
held by about an eighth of an inch once this is pressed all the way in on the hydraulic press
it gets a lot harder to move so this is a good stage for getting things to be set up
there we go
okay so i can't move it i don't have play on either side so they are pretty close so
we're going to go to the hydraulic press now and we'll press this in now i did take a measurement
of how how close these were 7 16 that that's the gap that was there so we'll have this as a guide
i put a little bit of an angle on here so that it would go in and that's about
that's about what it was so look it's got a little bit extra play here and over this side
a little tighter too so let's let's go set this up in the lathe now in between centers
and we'll and we'll check the run out and then we have to make adjustments i know it's not going to
be perfect the first time so we're going to the lathe now it stays the same nothing moves
there's nothing turning except for the flywheel and look at that so let's set this to zero
we're plus 10. so we we always make a mark that's plus 10 as in ten thou
now we have to measure this side here so there's zero right there
six thou so actually it's not out it's not out huge it's not perfect but not huge
so that's plus six let's go to the bench and
do some straightening okay so let's give this a hit right there
then we're back in the lathe just it's back and forth
okay so that moved a little bit now it's out five or six sow
and the high spot is it's it's still in the same spot about
so this is what i do i just change it
now it's plus six so we'll go hit it once again if we get this side straight and then we'll figure
out how to get this side straight we're looking for two thou everything has to be less than two
thou per side so i know how hard i hit it last time so i'm going to hit it about the same amount
sometimes this can take quite a while and sometimes it just goes really
smooth and it just all kind of falls into place
somewhere around there oh
okay so this is a really good sign we've got three and four and they're both in the same spot
that's that's the best news so far so we're looking for two thou or less okay see here
that's our line we got three thou four thou out and we are almost almost perpendicular
with the crank pin we're out off maybe an inch so what we need to do these are the high points
we need to squeeze this right here in the vise and that's that's where this piece comes in
because when we when we squeeze in the vise we want it to go
if i can show you with this we want the force to be like like so so if we don't put in a spacer
just gonna flex like so we want it to only flex like that if i'm making sense then so this goes in
like that and we can give it a little tap
and now we squeeze right here lightly it's just a small flywheel it doesn't take huge huge force
so i'm not gonna squeeze it that much
there we go we're at we're at nine o'clock if you think of a clock
he won thou
i'm gonna say that's one thou right there
we're good yeah it took a little while but that was that was good so yeah we're we're within
in the two thou boundary as specified by that magnificent haynes manual
if you're wondering why i started with such a big piece it's because i got the jaws in
outside mode and i have to hang it out that much that's why
there we go
okay let's go over and uh see if this fits
that's a good fit that is our episode for today how to actually we haven't even named this
episode at this point but that's what you do with a flywheel when you have a new rod and a new crank
pin and you press it together and then you have to align it a little bit of a fiddly jump hope
you have enjoyed being in the shop here you could always like and subscribe that'd be great mitch
and i like coffee if you buy us some coffees much appreciated see you next time stay safe
you