Saturday, October 30, 2010

Tanks For Nothing

If you pull your own wrenches, one of the most onerous jobs on a Boss Hoss is the removal of the gas tank. I intend to resolve that problem with a few easy modifications and a few home brewed parts. The first of these parts are two of these aluminum buttons (shown on the tile counter) that I made on my lathe. I measured them, mostly, by eye. The only semi-critical measurement was the small diameter, so that a short piece of 3/4" heater hose would slip on snugly. These bolt to the front mounting tabs of the tank and fit into these "C" shaped brackets that bolt to the original tank mounts on the frame. They will be welded in, later, since the weight of a full tank of gas plus the bouncing and vibration will, certainly, cause them to drop down. At the rear of the tank I tossed the original Adel clips (can you say Mickey Mouse?) and welded in permanent tabs that align with the tank mounts. All were drilled to 1/2 inch. I machined two more buttons with a half inch diameter that slides into the two tabs and locates the tank. I went to my local surplus house and picked up two of these quick release pins. They are 7/16 inch diameter. I drilled the buttons 7/16ths to accept the pins. I did not want to rely on the pins alone to hold the tank. I was afraid that the weight and vibration would damage them, so this is why I made up the little buttons. A washer with a 7/16 hole will be tacked to the backside of the frame mount so the pins will be able to lock in securely. Tank removal should take about 15 seconds. video

Sunday, October 17, 2010

Deja Vu All Over Again

Again, the bike sits in the same spot as it did when I began this blog, torn down, it's guts exposed to the prying eyes of the world. This is the final, planned, dismemberment. The primary focus this time is to put the belt drive back on, complete the mechanical fuel pump installation that I began a few months ago (I'll 'splain in a later post), replace the shifter with something nicer, clean up all of the welds and assorted boogers, paint the frame and side covers and reassemble the whole thing with an eye towards detail and eliminating any unnecessary stuff. I have all winter, so I plan on taking it, fairly, slow and getting it right. Plus, I still ain't got noooooo money, Honey, so I'll be collecting aluminum cans and selling blood to fund the project