Restoration of Sandcast #97

[markb]

Thanks for the nice compliment John. I haven't added anything for quite a while but hope to soon. I have some improvements and corrections to do. Things have been too busy and I've also had to move all my bikes and parts to a new location. I hope to start posting again by fall.
Mark

[Steve Swan]

Recently I asked a question and it was suggested that I read Mark's thread to get a deeper appreciation for the uniqueness and distinctions of a Sandcast, in this case a very early one.  I started reading and learned a lot, but also realized how little I knew.  After reading all 48 pages, I have a newfound respect (and envy) for all of you who have spent the time and efforts to return these bikes to their original glory.  Mark's 97 is amazing in its attention to the smallest detail.  These same details would seem insignificant to the uninformed, but those people would be missing important bits of information and history.

To share a thought that most of you have already had, it seems Honda did what they had to to get bike's out the door.  I'm very happy to have 2659 as it is, my first and maybe only Sandcast.  Many thanks to this sites members for their dedication and willingness to share their knowledge.

John

John, thank you for your heartfelt compliment, it is much appreciated.  a number of us have put in many hours to gather information, help others and learn as much as we can in the process.  Really all it takes is desire to learn and, willingness to admit when one does not know.

[markb]

After a long break I’m finally getting back into it. I have the correct head and cylinder now ready to install in E100. While I was at it I figured I might as well do three at a time. Here are the heads for E100, E748 and E1490. The head that’s in E100 now will go back where it belongs in E1789. I had all three vapor blasted by Nils at RestoCycle. Great work, really pleased. All three had complete valve jobs too.


Here’s E100’ head. You can see the where the missing spot faced holes are as outlined above. It had to have the tapped hole just to the right of the #2 intake valve repaired. If you look at the picture above you might be able to see it where the gasket surface was broken away.


It had to be welded, machined and helicoiled.

[markb]

The cylinder for E100 had a broken fin and had been bored to 1mm oversize. As I said that’s why I chose not to use it. But since the engine is coming apart for the original head I’m fixing the cylinder too. Here’s a couple of shots of the broken fin.


It broken off pretty deep so there was no way to weld on a replacement fin.


I had my welder build up layers to fill it in.


There was a lot of material to remove. At first I could only get a skinny file in so it took a while. I think I had 6 hours into it by the time I was done.


Here’s the finished product.


It’s not painted here but after I got it painted you can’t tell.


I had it resleeved and rebored too. And like the heads As long as I was doing it I did E748 and E1490 too. After I get 97 put back together I’m planning on assembling E748, E1490 and E1789 at the same time.

[Sam]

As always, I admire your patients and quality of work Mark! Keep it up. You are making the rest of us restorers look bad!

[Steve Swan]

Great work Mark!  very nice to see you back on the forum sharing your dedication to all things sandcast.

[markb]

Great work Mark!  very nice to see you back on the forum sharing your dedication to all things sandcast.

As always, I admire your patients and quality of work Mark! Keep it up. You are making the rest of us restorers look bad!

Thanks for the kind words. Not so sure I'm making anyone look bad except myself. If I would have done it right the first time I wouldn't have to do what I'm doing. It didn't take me long to decide that I had to do it. Just took me a while to get to it.  

The engine is out. This is just to document that it was, in fact, removed from the frame. Including removing everything that has to be removed first it took me about 4 ½ hours. It could have been 4 hours but I was taking it real slow so I wouldn’t ding anything.


And the wheels are off too. I need to have them redone with the correct spoke nipples.

[Steve Swan]

good work, Mark.  did you manage to get the engine out without leaving any marks?  i have to pull the engine on 232.  someday...  so, i know the feeling.  not dreading it, there is just so damn much care handling wrenches, holding bolts while tightening nuts, etc, etc.  it all takes time.  i've not had to dismantle a restoration, but i can only imagine there is stress on the paint where lock washers tightened against the paint an it could crack off when loosening nuts.  i have a "diamond/criss-cross" cam cover with the 8 early type adjuster caps i'd like to install.  someday...  i haven't even got around to swapping out the later alternator cover for the thin lip cover; that's the easy part  

[markb]

It actually came out really well. I should have taken some pics. I'll do that when I put the engine back in. I use a hoist and a variation of a "C" hook that is commonly used. You're absolutely right about the lock washers and nuts marring up the paint when they're loosened. There's not much you can do about that so there may be a few spots that I will try to touch up. Good luck on your project when you get to it. 

[42barab]

Step by step.  Hope everyone's days aren't too chaotic, what with the holidays and all.  Just got back two MC's and caps from being black chromic anodized Type 1.  Caps seem to have shinier finish than the bodies.  Is this the way they should look?  Thanks

John

[markb]

They do seem shinier than the bodies. It's hard to tell in the pics if it's too much. Do you polish them or did the plater? The anodizing isn't what made them shiny.

[42barab]

I had them stripped and polished locally (NJ), and then Sanford did the "Chromic Anodize Type 1, Cl 2, Black" (from their invoice).

[42barab]

The caps are much shinier in person.  Do these pics show the difference better?

[markb]

I think they're fine especially considering what it would take to "dull" them up a little.

[42barab]

Okay.  Thanks.  Have a great Holiday.