hi i'm paul brodie we're back in my shop thank you for joining us we're going to
work on the tiger cub today mitch is behind the camera and i never forget about mitch
we're going to work on the tiger cub and what i have done i'll show you a little bit of what's
new got a couple of brand new fins there i'm going to show you a photo actually two photos
of what went on that was not an easy job i've got the copper plate under the fin and to get access
into this fin i actually had to hack saw off this fin there was nothing wrong with this fin but
that was so hard to get the tungsten in there and i also had to shorten up the copper plate
after that all got filed up i put another copper plate under there and i welded up the fin that i
had previously hack sawed off so it's looking fine now but that was not easy i've just got
one fin left this is the one right over top of the exhaust port so i have to make a custom
a piece of carpet to go in there it's got to be really thin last one and then the head goes out
for valve seats so that's some good progress what we're doing today is we're going to work on the uh
on the brake cable and i've got a bunch of stuff here we've got to make ends things like that what
i'm starting with is outer cable got a piece the right length and i've also got inner cable but the
end is the wrong size so we're going to make one out of out of brass we're gonna soft solder it on
and then we have to make all the end pieces we need an end piece for each end we're gonna make a
delrin slider so that when the forks compress and the cable comes up it can slide through the delrin
because we have one on the bike right now that's made out of out of steel
and it's got sharp edges does not want to slide and we also have to make the bottom
pieces so there's a few little things going on and then i want to i think
we'll have time we're going to repack no not repack we're going to pack the muffler with
fiberglass so that hasn't been done yet so couple things going on let's get started
got a nice light here
thank you mike
i told mitch i think i can get this whole cable done in an hour and a half so
there i am probably being optimistic again but we know when the clock started you don't
we'll be honest with you okay
so this is the test oh look at that it goes right through so perfect
there we go we got brand new end i did this before in a video but that was a long time ago so
it's good to do it again it'll refresh my memory
so what we want to do is to flare out the end
see see it flaring that's what we want we want it to flare
and then we pull it down a little bit like that flux it up solder
so we're going to heat this up too hot you just want the silver to flow into the
into the actual cable and fill up that chamfer
yep there goes some salt oh see that
that's it that's all we do that won't come out
oh yes look at that okay so the second thing we have to make is we need a piece that goes in there
that's going to hold the cable a ferrule i think you call it a ferrule
do you see how the cable won't go in there so we need a piece that comes over here
steps down and then goes into the into the adjuster so got some metal let's go to lathe
okay
so
that goes in like that and that goes like that so everything is good
because this wasn't working at all you could take off the plastic and then put this inside but
that's mickey mouse doing it that way okay let's go put this on the bike and i'll show you what's
next see this here that's going to hold the cable but i don't like it because it's got sharp edges
and the cable isn't going to move freely so this is where we're at right now we got one two
so this is going to be an arc like that and then as the wheel moves up and down this needs to slide
in here so that's where the delrin comes in we're going to make a new one of these
it's going to have a larger hole the bolt's going to get
sunk into the delrin and we're going to make some kind of a shape i'm not sure what so
so this is what we have we have a bolt that goes in and we have a socket which
turns the bolt and it all fits in there so the next thing to do
is to make a hole here okay we're doing an experiment here this is delrin we got a
a 20 millimeter end mill with one broken flute that i just it dropped so
we're just gonna see what happens if i can plunge it right down
that seems to work pretty well
so that's the rough shape it can be fine tuned maybe maybe this will be made a
little smaller here i don't know but that'll that that's going to get us going right now
and it's black it kind of blends in with the bike i know it's not standard it's not a restoration
but just having fun that's all
okay so the cable see that it can slide
quite easily now so what we have to do now is to make a piece to go into here
no
there we go that's the that's the feral
there we go so we just have to make these pieces now that's all
no
a little bit of oven spray there off there off the tapping fluid
okay so we just have to make the piece that goes on the bottom now that holds the cable
and then we'll have a front brake working
so i need to start straight this way and this way looks okay
i got a spiral point tap so i should be able to just go straight through
okay that worked okay
we're doing installation now we're gonna
mark this up see how it works i haven't lubed the cable yes i know that but it's gonna come apart
and probably a few things will get fine-tuned like this this big delrin piece it'll be made
a little smaller but you'll get the idea of what what's going on here
so the cable fits in comes up like that we need a little bit of slack
there we go look at that we have a break so i told you at the start of this we were gonna i was gonna
see if i can do it in an hour and a half and it actually took well it was two hours and 15 minutes
way over budget over time over budget that's the story of my life basically i always overly
optimistic about how fast i think i can do something so you think i learned by this time
okay we're going to work on the on the silencer now the muffler we're going to pack it
see how that works i have a bag here of exhaust packing i've had this for quite a while like we're
talking years maybe even more years than that so we'll see if we have enough now one of the things
i've been thinking about to tell you is that everybody tells me that you gotta pack it tight
no one ever complains you pack my exhaust too tight i've never heard that so
we're going to see what we can do here and i don't know how many pieces i have here
so let's look at the pipe if i wrap it around this it's got little little bumps here on the seam
i can't slide it down there so if i want to pack this really tight i can't get it down and down in
there so what i've been thinking of is i'm going to cut a strip which is this long and that's going
to get wound and then what i'll do down here i'll take some small bits and i'm going to i'll take a
wooden dowel or something like that and i'll pack them down there as much as i can so that's my plan
and i think i'll cut strips off here maybe about the same size as this and
that's what i'll use to jam down
inside you know if there's an expert out there you can share some insights
you know where the comments are i know you know where the comments are
i'm so curious as to what this is actually gonna sound like this muffler
so
okay i think this part of the muffler is pretty well packed
i don't think it wants to go down much more
so here's the six inch that's gonna go here
oh it is a bit long okay well it'll just squish down that's what i think
a long time since i packed a roughly back to muffler
okay that doesn't want to work like that so we got to go around
okay so what that means is that we can put more and more on there we need more
six inch strips because this should be tight
okay we'll take off the tape here because the tape isn't going to help
there we go muffler-packed
seemed like an action-packed day that's what it seems like to me i don't know about you
but that's that's my perspective so we did a brake cable on the front for the tiger cub and we
packed a muffler so i have a good sense of accomplishment for that
thank you for being in our shop i hope you enjoyed our show mitch and i like coffees
if you buy us coffee it's much appreciated you take care stay safe see you next time
you