The Chopper Compendium

Well, once again I seemed to have got another oldie in super sad shape to rebuild.

This one is a 1937 UL;
Thought I would start at the top and work my way down.

Here's what I had to work with... Mostly rust from 30 years of sitting....
First off was a wash up ...Then a blast.

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New valve parts went down...

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A set of sleeve was ordered....

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Some boring, leavening .003 for a press fit.


Bore was out to .060 over and had way to much rust to go even to max. oversize...

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And a few deep dings...

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Heat the jugs to 450 degrees and push them in to their new home...

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Some more boring and done deal.

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Next on down the list will be taking a hard look at some more rust in the cam area of the motor....

Great work. Looking forward to seeing this one come back to life.

Thanks....

Working on the gearcase stuff....

After a wash and blasted, cleaned up very well...



Did the red thing... Baked for two hours at 250 degrees....



Cleaned up the OG cams.... Got a huge amount of backlash going on with these and mega rust on the face of two lobes and the gear faces...



Looked like a set of new cams would be needed to cure those problems...



Ordered these Bad Boys.....

Kinda got a little wonder going on with the AP cams....
The OD of their shaft that goes into the motor case is .684.... What OEM stock cams have going on is .686

I'm replacing all the bushings in both the case and cover....
Thinking about making up custom bushings on the case side to tighten up that .002 diff.
Wonder why they made them that way....?

Some more info on this little problem...

Talked with Jeff at Eastern M/C Parts...
They make the replacement bushings.
His ID of those case bushing is .688, which would be a drop-in and run deal with the OEM cams...
Hardly no work will be needed for the fit, being it's built right into the new bushings....

But with the AP cams being two thousandth under stock, that will be running a .004 loose fit, right out of the gate...

Soooooooo, Time to make a set up .... being the running fit is .001 to .0015 , Will finish the ID at the speck of the AP cams (.684) leaving a little meat to hone/ream out to min.speck...

On another note:

.... Had another chat with AP Tech Guy.... He said that the .684 is on his blueprint and that is the correct size for the shafts....Also said that it would take more than one Po-Dunk Hillbilly telling him that his blueprint is wrong before any changes are made to it !! .... All rightly then.

It's up to you other Hillbilly's to call in and say sum-en .... .... AP 847-759-0190 ... Tech's name is Gary...

Just a caution...

I have no experience to share, but I have recently seen some remarks critical of shims purchased from Eastern.
Too brittle due to incorrect hardening?

Not even sure if this is the same Eastern, but would hate for you to get deep into this and have problems with
sub-standard parts.

Can tell you are checking thoroughly, I appreciate what you are sharing, interesting.