Restoration of Sandcast #97

[kp]

Hello Mark
You do not have the right cap oil on the photo that is a 14 mm on your engine, while it should be in 17 mm, and it seems to me also from memory that your regulator has a sticker for references while they must be painted, and also that your oil pan drain plug is too recent, it must be the same as the oil tank drain plug...

My friend from France is very observant, however the regulator does have a sticker and not paint.

[4pots1969]

I am very attentive in detail because the restoration of Mark is very interesting, it is like my bedside book when it is very late at night and I can not get to sleep...

[markb]

I took some time this weekend to go the Minneapolis Motorcycle Show.


The local chapter of the Antique Motorcycle Club of America asked me to bring 97 to display.


That’s why I needed to get it back together.


I answered a lot of questions. It’s amazing how many people have at least heard of a sandcast.

[Steve Swan]

without a doubt, people who are into motorcycle's are aware of sandcast because of the collective experience of sooc.

[vnz00]

Nice pics Mark

[Sam]

One of the best-restored sandcasts that I have come across. Well done Mark.

[42barab]

Mark

Did you do the paint work?  It looks gorgeous!

John

[markb]

Thanks for the compliments guys. No, I am not a painter. It was done by Vic World's painter. His name is Blake Conway in Vista California. His number is 760-732-3950 if you would like to contact him. If you do tell him I said hi.  

[markb]

My latest project is working on restoring brake disks. For now I have a NOS K1 disk until I can replace it with a correct restored one. I made a special tool for grinding the disks on a surface grinder.


I’m still experimenting but here’s where I am so far. Before…


…and after.


If you’re interested here is a thread that shows a little more detail about what I’m doing starting at reply #45.
http://forums.sohc4.net/index.php/topic,175601.25.html

[bojje]

Hi Mark!
Looks very nice. With a repaint of disc-hub (not rivets) it will look like new. Next time: start with glasspearl blasting before grinding. When painting the disc-hub after blasting and grinding it will be perfect.
Kind regards, Bo from Sweden.

[markb]

Thanks. Yes, my plan is to clean up all my disks before grinding so that the only thing I have to do is mask them and paint them. I wanted to make sure the grinding looked OK before taking the time to do the cleanup.

[markb]

I’ve finally finished restoring the brake rotor. I think it turned out pretty good. The masking was a challenge because of the spokes and the rivets on the inside.

I tried different tapes and trimming with an exacto knife but couldn’t get decent results. I finally made a tool that has a hole the same size as the diameter of the rivet with a flat land around it.

Then I drilled the same size hole on the other end and machined an angle to make it sharp.


After trying masking tape, vinyl tape and some others I found that the tape that worked the best was duct tape. The flat end of the tool formed the tape around the rivet head.


Then the sharp end trimmed the tape perfectly.


Here’s a pic of the finished product on the outside…


…and the inside. Now #97 finally has a correct rotor!

[Joe K]

Very nice work, Mark!

Joe K.

[kmb69]

Those are beautiful, Mark.

[markb]

IT RUNS!!  I took #97 out for a short test ride last night. It’s tuned up, carbs synced and sounds great. I only went about a mile. Ran it up to 60 and through all 5 gears. Everything works. I have about a 15 second video (28MB) of it running that I would like to post but not sure how to do that. Can anyone point me in the right direction?