EVOlyn

[EVOlyn]

December 18, 2007
Hello all, my name is Larry. I picked the forum name EVOlyn for a reason. Three years ago I purchased a 1928 Frazer Nash kit car built on a 1968 VW. It was a mess, brakes frozen, no fuses in the electrical system but it was a cheap re-entry into hotrods. Rebuilt the entire car and have driven it in a couple of home comming parades at the local high school. It is so cool driving on the other side. Unfortunately the tires are not exactly round so speed is limited and hense I got bored with it.

Started looking around for another kit car, a Bugatti, but somewhere along the way my oldest son said, "stop treating it like a 1928 Frazer Nash, it's just a cheap fiberglass kit car." Well, I took a whole new look and decided to make a roadster out of it and IT will be called EVOlyn. Why EVOlyn? Because it is going to have an 80 EVO Harley Davidson engine in her. Nothing sounds like a Harley, so I thought that would be way cool. Fenderless of course with an all wheel conversion to disc brakes. I have the engine and am working on the shopping list for the rest of the parts.

I have never done a multi make conversion and while I'll admit to being a little nervous about it, I'm also very excited. So here are a few photos of how she looked...

Oh yea, it is right hand stear...

and from behind...

I got to drive it fenderless before I put it away for the rebuild...


1st wee k of Jan 08 progress
One of my neighbors said it best, "... you'll take it out, you're a perfectionist." So, as he said, I pulled the transaxle. We had a warm weekend so I took it out on the drive and degreased it with the power washer. Ready for paint.


Warm weather continued so I couldn't resist a day off work. Drug out the pan and power washed it. Ready for a coat of Corless and painting.



Things to come... the original on the left, rear in the middle, front on the right...


Here's the Harley EVO engine and the original 1500...


Here are tow pictures of the pan after a thorough cleaning with the grinder and sanding wheel. Also removed the old frame work up top. Iforgot how much I hate breating rust dust! YUK!


And the new parts from Cip1


The parts still needing to be cleaned and painted.


Well, things went slowly this week. I did get the front calipers painted and the Front rotors & spindles. I intended to clean up the rest of the parts but ended up working on the pan again. Tried welding some holes closed, but the pan is so thin I had trouble burning through. That made me doubt weather I should cut the sides off like I was planning. Well, sometimes you just got to go for it, so I goth the circular saw out, put on the metal blade and... The damn thing burned up. I can't complain, it was my father in laws, from Wards. So, off to the store for another one. I AM going to cut those sides off, then I will have to replace them.

Here's a couple of pictures after cleaning up the tunnel and removing the stock ebrake.



February started out on the low side. First I got an email from my Harley to VW transaxle – he bailed on me, said he no longer makes the part. I thought that was the end of it, but the folks here at volksrodder gave me some options. I haven’t been able to confirm anything yet, but at least there is still hope.

In the meantime, I’m investigating other options (Corvair engine of VW engine up front, Harley engine up front, or just a nice mild street VW engine). Hopefully something will shake out this week.

No pictures, but I got the angle iron on the sides removed. Cleaned up the front trailing arms so they’re ready for the new lowered ball joints. Also cleaned up the starter and got it painted.

Feb 5, 2008
GOOD NEWS! I have located another adapter for the Harley Davidson to VW transaxle conversion. It aint cheap and there are issues if anyone else is interested. I’ll follow up with details once I get solid information. Thanks to all who helped.

EVOlyn is Alive again!

So here is how a Harley engine is adapted to a VW transaxle (as I have been told)

First off, the adapter is $2200 as of Feb. 2008. It is the product of a lot of testing and design improvements The adapter is used (and can be purchased from) Rewaco-Trikes located in Arizona (702-651-9057). They have a V-Twin trike that uses the adapter. They are very helpful and informative. You can also get the engine from them.

Now, about the engine… As you know I purchased a Harley Davidson EVO or Evolution engine with this conversion in mind. While most of the testing with the adapter was done with the EVO engine there were issues. The EVO would setup a teeth rattling vibration at around 2800-3000 RPM. There were also issues with the charging system overheating. The good news is the adapter has bearings that resolve all the previous failure issues associated with this conversion. Rewaco eventually replaced the EVO with the newer Harley Davidson Twin cam B engine. Note there is also a twin cam A engine. The important difference is the B has a twelve pound counter balance that resolved the remaining issues with the EVO. As the Rewaco representative told me, “we put on the twin cam B and all the remaining issues were gone.

For me, it has been a difficult and expensive journey I just hope when I finally finish I can look at the end result without feeling the pinch in the pocketbook. I have the new Twin Cam B engine on order so at the present time I have the old EVO and the new on order. $$$ OUCH! Fortunately the vendor has agreed to swap the engines. It will mean a road trip to North Carolina, but I can’t afford to pay shipping for both. Time frame for the new engine and the adapter looks like mid March, so I’ve got tons to do until then.

This weekend I cut the shock towers, here's what I did...

OK, you know what they look like

Cut them off using the template on the left, then used the towers for the tops (template on the right

Weld the pieces on... I used a stick welder at 60 amps. Nice thick steel, no problem

Grind everything smooth

Primed, ready for a touch of filler and paint...



Trial mount


Steering mockup


So here's a sketch of the center steering idea.


Sat. Feb. 16, 2008
Picked up some steel yesterday and got to work on the side frame rails. This morning I finally bought an autodimming welding helmet OMG! has to be the greatest thing ever. I can actually see what I'm welding. So here is a couple pictures of the passenger side frame rail...


Now if I can just make a mirror copy for the drivers side. Maybe tomorrow, the 'ol bod gave out. Time for some R&R

President's Day 2008
So, as you can see from the photo above, the side rails stuck out about 3/4" past the steering head. Well, that turned out to be too much so I had to recut the pan and then notch the side rails to go around the lower bracing of the steering head.
Making the mirror copy for the driver's side.

You can see the 1/8" x 1/2" ridge I welded to the side of the rail for the pan to sit on

And here it is, everything tacked in place.

The trailing arm seals came in today so as soon as the shop gets the ball joints pressed in I can assemble the front end.

Jeeze, went by the shop today and they still haven't touched the ball joints. I was going to take them with me and find another shop, but they promissed they'd do them tomorrow. Fingers crossed.

Got home to find the rear disc brake kit arrived from Cip1. Damn! A nice looking kit and it even has instructions. Got my work cut out now... can't wait!

more to come...

[EVOlyn]

Just got a call from Tom, the new Twin Cam B engine has arrived at his shop. Time to plan a road trip!

On the down'r side, the guy who was supposed to do my ball joints couldn't. Not really sure why, but after a week I have to find another place to do them.

Well, got the side rails welded on & the pan stitch welded. Painted with Coreless and then caulked. Once the caulk is dry, will paint underside and sound deaden.



Started in on the transaxle and it's one of those things I wish I hadn't started. Realized after taking the small sides off I can't get them off the axle tubes without removing the other ends anyway. Guess I'll have to clean them up on the tubes. Oh yea, figured out why the old boots split. I clamped them on with the wheels off the ground, so the axles were in the down position. That meant when I lowered the car, the bottoms of the boots were stressed eventually tearing. Won't make that mistake again.



Picked up the new engine on Friday March 1, 2008. After 13 hours in the drivers seat my ass was killing me. But hey, it cost $100 in gas but I save the $350 shipping. Whoa, the Twin Cam B is a much more substantial looking engine. Who knew eight cubic inches would make so much difference. There are parts I need to get to complete it and Damn! motorcycle parts are expensive! Oh well, I'm knee deep in it now, but it's going to take some serious wife soothing to get it finished. Post some pictures toward the end of the weekend.

Wow, it felt so good to actually put something together for a change. Hopefully it will be the start of things to come. It's been a long winter. I still can't believe it, but I got the new one piece boots on over the end of the axle tube. If I hadn't been told how and that it would go, I never would have believed it. Painted with a dark gray metalic that will be followed with buffing the paint off the top of the ribs to polish them, then clear coat. Here it is so far.

Also cut the steering limiter off the pitman arm (fenderless roadster so I can see the tires), then cleaned and painted the steering box.

Thought I'd never get it finished, but finally got the understide of the pan painted. Coat of rubberized undercoat on the pans.

Weather was warm, so I got to air out the garage a little. Also polished the raised ribs on the transaxle then clear coated it. The change is subtle, not sure it will even show in pictures, but it looks great IMO. Hope to fabricate the center steering support this weekend.

Polished the spines then clear coated everything.


Well, I did some subtle silver highlights on the raised ribs on the bottom of the pan. May never be seen again, but it didn't take too long to do.


This is the big accomplishment this weekend, the mount for the center sterring. As you can see, it is in the process of being painted.


I'll get some better pictures as I get it closer to finished.
more to come...

[EVOlyn]

Well, my daughter got her first car this weekend and while it's not a VW, it's a nice reliable 2006 Cobalt. Not too spoiled huh?

So, I finished painting the front beam. It's ready to have the trailing arms installed so I'll be checking the tech forum for how to put it all together.


Also painted the rear fork on the topside, so it's ready for the transaxle.


Last, but not least, I got new emergency brake tubes installed and fabricated a mount to put the lever on the right side of the tunnel.

So it's starting to slowly come together. I got word from the wheel manufacture that the wheels should ship sometime this week. I'm still trying to get all the pan work done while it's up on saw horses, but once that is done, I'll be putting it on it's wheels. Thats a big step! With the weather warming up, I'll soon boot my wife's car out of the garage so I won't have to pile everything up on one side during the week. Should be able to get some things done during the week that way. Well, thats it for now.

April 1, 2008
No new pictures, but I thought I'd post the progress. Last night I buttoned up the last hole in the tunnel. I also finished cutting down the pedal assembly and relocating on the tunnel. Finished running the accelerator cable and clutch cable. A little Bondo and the tunnel will be ready for paint.

Sunday I reassembled and inserted the spring packs. Also installed the new seals and attached the trailing arms. Going to be away this upcomming weekend, so no progress, but I should have the pan down on the wheels soon. Now, if the wheels and engine adapter will just show up!

Here are the pics...




Damn! Talked to the wheel place and still no ETA on the wheels. I ordered them December 28, 2007.

and...

Still no adapter!
more later...

[EVOlyn]

Well, I thought I had problems with the transaxle. I went to install the disc brake conversion and the axles appeared to be too short. After a lot of grief and some coaxing along (thanks Fran) I determined the rotors are the wrong ones. I'll be working this out with Cip1 this week.

Now for the big news, The Rewaco Twin Cam B adapter arrived. This is a formatable piece of hardware. It looks awesome! Can't wait to get the transaxle back in the car so I can do a test fit. Here are some pics...







So... It really does exist!

more later

[EVOlyn]

Well, its been a bit since I posted any pictures. The project is going slowly, but I'm making progress just the same.

I got the front end all put together and mounted, but I've discovered the center sterring is creating some unexpected issues. The main issue is it doesn't leave much room for the gas tank. Been looking everywhere and I can't find an aftermarket tank that will fit. Kind of don't want to make one from scratch, but it is a possibility.

The big news is I finally settled on seats. I got the rear seats out of a Honda Prelude. They look pretty sweet and are the closest to what would fit. One of them even folds down. Think it will work out fine. Here's the pics...







The front end...



Sunday 4/27/08
Spent most of Saturday fabricating the master cylinder mount. It seems plenty stout and as luck would have it, it left just enough room for the battery. Pretty damn sweet! I couln't have planned it any better.

At this point I'm about 90% committed to fabricating my own body and with that in mind kind of thinking of making no hood on the front. Access to the small storage compartment would be through the passenger's side like a huge glove box.

Well, besides the master cylinder I spent the afternoon mounting the Twin Cam B. With the adapter attached it turned out to be more weight than my wife and I could handle so I used the frame from the deck swing and an old block and tackle as an engine hoist. I am super pleased with how it looks on the car. Although the Rewaco adapter isn't cheap, it is one well engineered piece of hardware.







Here is what the skeletal side view looks like...




Going to try and finish that novel I've been working on for the last three years today!
Thats writing the novel, not reading it!

May 2, 2008
Well, I finished the novel! Wife's proofing it now.

You know that 90% sure I'm going to fab up a new body? Well, that means 10% sure you're not.
Really want to get this thing on the road in some fashion this summer, so... I drug the old Frazer Nash body out of the shed and set it on the new frame.




There are some issues with fitting around the Harley engine and driver location to the dash, but nothing to difficult to change. I intend to abbandon the gleaming, new look and go for a more traditional vintage roadster look, at least for now. I will still have to do some fiberglass work, but it will give me a chance to give it a try. Looking at bringing up the sides to get rid of the English look, new rear and nose, possibly even doing a split window, then their is considerable work needed in the rear tire area of the body since it was cut out for fenders.

Right now, after the fiberglass work, plan on painting it satin black.

Right now it looks like I need to bring the dash forward about 8". I plan on moving the body about 6" and accomplishing the other 2" by cutting the cockpit over the dash. This should give enough clearence for a comfortable ride and also get the body to clear the engine. I think once I get everything measured, the nose will actually end up forward of the front wheels. A much different look than the original plan, but might be cool.


Keeping in mind what the Frazer Nash body looks like, I'm hoping to go for something bewteen this

And this

Time will tell!
Oh, and by the way, those are the wheels I ordered on December 28, 2007 Last report... they are in production. Yea, like I haven't heard that before.

May 11, 2008

Slow progress, but I got some steel bracing added for the body mounts.


Also discovered some issues...
When I set the front end down on the trailing arms, one side touches the other is about 1" up in the air. To me that means trouble with weight distribution with more on one side than the other. I removed the sway bar thinking it might be a problem, but no effect. If I stand on the front, they both touch down. Put a level on the beam and it is level so to me that means the torsion springs are different. Not sure what to do about this but I think it will cause a handling issue.

Also have a design decision. Here is a side view of the nose.


The front is close to ride height and the tire will come to almost the nose as it sits. Obviously by adding to round it off, the nose will stick way forward of the tires. Not sure that will look good. I have the option of cutting the nose back, basically shortening it. Not sure which way to go.

Saturday 5-17-08
Not much been happening, the ol' bod just isn't cooperating. I did get the gas tank back. The $200 estimate turned out to be $350. Ouch! But it looks cool. Post some pics later.

Had hoped to get the steering installed this weekend, but we got a dumpster for the neighborhood so spent the day cleaning up the yard. Only good thing about it, I now have room to extend the shed. Hoping to put the car in it over the winter. If, BIG IF I decide to make a body, that would give me room in the garage. Still hope to get it running in some form this summer. Fingers crossed.

Well, got some pics. Here is the gas tank


Couple shots of some additional bracing for the body




Here is a 3/4 shot with the grill shell. Not sure if I'm going to use it.


and a side view


Just got word the wheels shipped today! Can't believe it, finally. Ordered them 12-28-07... now that is lead time. At least I got a good deal on them. It will be awesome to see them on the car.

5-26-08
Health still keeping the progress slow, but I got the wheels mounted. Looks much different than I thought. I LOVE IT!!!

Rear discs


Front discs & the front end came down nicely when I set it on the wheels


Fromt the front


From the back


Nice and low


3/4 shot


Well, it's just a mock-up, but I'm real happy with the way it's coming out. Hope to get some work done on the body bracing and then work on repairing the fiberglass.

Well, it's June 7th and a sad realization has set in. As I'm sure the slowness of this project has become obvious, I had hopes of getting it into some kind of driving condition this summer. Well, I've been struggling with a yet undiagnosed condition that makes it very difficult to work on the car. I've been doing my best, a little at a time. The wife had always siad I wouldn't get it done. Hate it when she's right. Anyway, I've come to accept the fact that it aint getting done this summer. Got to be one of the most frustrating things ever, but can't ignore the facts, just hurts to damn much to work on it.
The doctor said I most likely have some form of cronic lyme disease, so if they can ever figure it out there is a treatment, which in and of itself will keep me away from the project for awhile. Hopefully when I can get back to it, it will be fun again. For now, I know what it feels like to be 90 years old.

Well, progress has been almost nonexistant, but I managed to blow the dust off and do a little. Not really sure why, but a coat of primer on the frame really seemed like a lot of progress. I also managed to make brackets to hold the steering column. Hey, its something.

Oh, and since I can't get the project done this year, my wife said, "YES!" to a substitute toy.

more one day...

[EVOlyn]

Well, it's mid August and the kids go back to school on Monday. Damn the summer went fast. Since I couldn't work on the car over the summer, I went ahead and finished a book I've been writing, it came out real nice. Might even look into getting this one published.

On the medical front, it seems like I finally have a diagnosis for the long term ailment that kept me from the project this summer. Instead of Lyme disease, the doctors discovered a problem in my neck. Seems like three vertebrae are pressing against my spinal cord and that interrupts the signal to my brain which in turn makes all my limbs feel weak. Good news is it can be fixed, bad news it means major surgery. They are going to try some kind of injections in my neck to see if it helps which would confirm their diagnosis. Then we'll see. And oh yea, the doctors don't want me to ride the motorcycle cause the helmet is heavy. Yea right!

As far as Evolyn goes, I've managed to do a little. I got the gas tank mounts made, the steering shaft completed and the tierods done. Basically all the steel work in the front is complete. Don't have any pictures at the moment, but I'll try to get some up in a few days.

November 2008
Can't stand seeing the project just sitting there with no idea when or if I can ever work on it again. I've decided to put it up for sale, it's listed in the parts for sale section on this site.

March 2009
No progress on Evolyn, as a matter of fact, she went up against the garage wall under a tarp. Usually means the death of a project, but I still hope to get back to her since there was no interest in buying her.
My medical condition remains unchanged, but there is new hope something can be done.

May 2009
Nothing new on Evolyn, but I had a few more injections and I decided to use the time to extend my shed. It is now 10' x 16'. I'm hoping to finish it this summer and hopefully do a little on Evolyn after that. Not much, but something.

July 2009
Well, the shed is finally done, a slow tedious project that should of probably only taken a couple of weekends, but hey, its done. Promised my daughter to put some stripes on her car, so that comes next and then if the ol' body holds out I'm going to try and do a little on Evolyn. Hard to believe another summer is racing past and nothing is happening on the project.

[EVOlyn]

Well, it's August 2009 and with the summer almost over I've managed to clear my project list so I could give Evolyn another try. Family went to St. John's for a vacation and snorkeling two hours everyday did wonders for my back. I know it won't last, but I've got to give Evolyn a go.

Pictures to follow, but here's what I did. Cut some of the upper framing off the nose. I figure I'm not going to need it.
Painted the floor with Duplicolor truck bed liner, came out nice and should be very durable.
Patched up a few places on the tunnel with bondo, smoothed and primed.
Next step is to drop the rear spring pressure one inner tooth, I don't think the Twin cam B is as heavy as the VW engine and I'm not going to have much body back there anyway.
I'll post some pictures soon.

1st of September already. Progress has been slow, but my wife says she thinks I'm doing more so the spinal therapy must be helping. I joined a Harley Davidson forum so I could learn more about my engine. Turns out you are supposed to have a title with a motorcycle engine. I contacted the shop where I bought it and they are looking. I'm debating between starting the body and getting it in running order, kind'a like a go kart. Both have pros and cons, so it's a hard choice. The runnable option is definitely more expensive, but would be such a huge emotional boost. The more I think about it though, seeing a body take shape would be a huge boost as well.

Making some progress on the rear framework, but have to replace some of what I did because of clearance issues with the shocks. Good think I checked, better now than later. More Pictures when I get something worth showing.

September 2009
Finally finished fabricating the rear frame structure and got the brakes plumbed to the flex line attachment points. Here are some photos.

Close up

The brake proportioning valve

Front plumbing and center steering shot

October 2009
Got the stainless lines connected to the brakes with the banjo fittings, looks real nice, a smooth flow from caliper to brake line. I like.
Hooked up the electric fuel pump. Doesn't seem like much, but exactly how to do it has been bothering me. Not sure if this is the best, but it will do until I see how it runs.

October 17, 2009
Got the ebrake cables shortened (thanks Fran), attached and everything adjusted. Started bleeding the brakes and found I left a lot of the brake line fitting lose. Got everything tightened up finally and starting to get a little pedal.


Used a gas pedal from a Chevy S-10. Some bending and a little nip tuck and it came out pretty nice.

The Harley engine electonics are all ordered, so when they come in, I'll pull the engine and get it all hooked up. Going to mock up the wiring so I can test run it. Still waiting to here from REWACO on some of the exhaust parts. Got a local quote for the exhaust and it was out of sight.



Oct. 24, 2009
My daughter helped me finish bleeding the brakes. I wound up flipping the steering arm, didn't like the angle of the tie rods. With it flipped, they are almost parallel to the torsion tubes, figure that should minimize bump steer. Also drilled the holes to mount the seats.

The charging system, ignition module & coil and plug wires came in, so I have almost everything I need to set things up for a test run. Finished the wiring design. Still nothing on the exhaust from REWACO.

I'm thinking at this rate, it may be possible to take a test ride (go-kart style) by the end of November. That would be huge!
more later...

[EVOlyn]

November 2009
Okay, so by now if you've been looking at my recent pictures, you're starting to wonder why everything looks like it's covered in glitter. A few weeks back when I was making the bulkheads (I use old street signs) I decided to use the wire wheel and get rid of all that reflective stuff from the sign. So, you guessed it there are little reflective pieces all over the freak'n car and garage. I've vacuumed, wiped everything down, and you can't see any, but the flash on the camera brings them right out. Drives me crazy.

So anyway, pulled the engine and installed the stator and cover, but got hung up with some details of the installation so I had to stop until I can get some answers. Used the frame for the back porch swing to pull the engine, figured if it can hold my wife and I it can certainly hold the engine.



The charging system

So hopefully I'll get some answers soon and get this put together.

December 1, 2009

Okay, so this isn't actually a project update, but a Huge deal just the same. November is National Novel Writing Month, a contest for writers who attempt to write 50,000 words during the month. This was my fourth year after a bit of a break. Previously I made it over the threshold only once. Well, I did it this year writing a whopping 54,375 words. The manuscript isn't complete, but I think I'm within 10,000 words. This is a great story and I am so excited to finally see the light at the end of the tunnel.

On the project, I've made some progress, getting the charging system installed along with the flywheel, clutch and pressure plate. The engine is mounted back on the transaxle. Got slowed down with some wrong parts when I went to install the carb, but they correct ones are on order. I have a few pictures that I will post as soon as possible. For now, I'm celebrating my NaNoWri victory!

December 2009
Finished installing the carburetor. Had a lot of difficulty finding connectors for the quick release oil lines on the block. Get them made around $240 After market from Harley Davidson $162. Took a chance on the place I got the ebrake cables shortened and got them for $30! Major score!

Still need to hook up all the electrical, but getting closer.



March 2010
Health has minimized progress, but I made up my mind I was going to do something, so I cut out the sheet aluminum for the rear trunk deck. Turns out we have a nice brake at work, so I took it up there to bend. Nice to use the proper tools.

Started cutting tubing from the Harley header kit I bought, so hoping to mock up the headers.

Doctors have given up on my spine being the cause of my problems which at least means I don't have to face any surgery. They are sending me to Hopkins to do some tests for rare neurological diseases. Weird!

Mid March - Did another, "no matter what I'm getting something done" Saturday and mocked up the headers. Unfortunately I eye balled it and well, they're just not straight, plus the one on the left (from the back) is too close to the oil lines I think. I could see it melting the rubber hoses.

So, I'll have o cut it up and make adjustments, but it is mostly just tack welded, so it shouldn't be too bad. Fixing it will be my next, "no matter what Saturday."

Here's a few photos...

From the rear


From the side


First weekend in April 2010
Planned to work on the throttle linkage and final header welding and adjustment, but I thought hey, I'll throw on the camber compensator (CC), it's straight bolt up, and it'll get one more piece out off the floor. Well, the outer cups interfer with the shocks and the brakeline couplings. Wound up disassembling the rear again. Cut and moved the brake coupling tang from the front of the axle tube to the top. While I had everything apart, I made the final adjustment to the rear torsion bars. Repainted the axles, and hooked everything back up, even tightened the axle nuts to final torque, came out pretty nice.

So, I still have to finish up the headers and make a throttle linkage, but the pan is sitting back on its wheels. Progress feels great!

April is almost over all ready.Using some cables from the seats my son bought for his Camaro, I was able to figure out a descent throttle linkage. Of course 'while you are there' and I wound up cutting and splicing the clutch pedal to make a little more room between clutch and brake pedal not so much for me, but if my boys want to drive it--BIG feet!

I was unable to locate any 5/16" fuel line fittings so I am going to go ahead and use the 1/4". I relocated the filter up front and the fuel pump to the left rear frame horn, near the axle. Hopefully it will supply ample fuel to feed the Harley.

Hope to get the new brackets all cleaned up and painted by the weekend.

Busted! Just noticed the rear axle seals are leaking again. Sucks! Like they say, two steps forward, three back.

Well, ordered the 17mm spacers for the rear axles, hoping that will resolve the leaking issue. Thanks to the guys over on the Harley Davidson forum for setting me straight on hooking up an oil cooler. Going to order one in the next couple of days. Also finally got the details on some baffles for the headers and got those ordered.

Fabricated a splash shield for the coil and got that temporarily mounted. Things are coming together as long as my health holds out.

On the health front I had my appointment at Johns Hopkins. Still don't have all the test results in but they are thinking I may have some kind of muscle disease. Only time will tell, but it feels good to finally be moving forward on this.

Here is a picture of how things stand. I got the coil mounted and wired. The ignition module temporarily mounted and partially wired. Have to resolve a plug issue and the regulator mounted and wired. Also made a temporary mount for the ignitions switch. Not much longer and I may be able to test fire it.





Waiting for parts, just do'n little stuff.

New seal kits and spacers arrived. The new spacers are not champhered so if that was the cause of the leak, these should take care of it.
Also ordered the exhaust baffles and oil cooler. Feels like things are starting to come together although slowly.

Reinstalled the new seals and spacers. My daughter graduates high school next Friday so no new work this week. Oh what the heck, here is a picture from last weekends prom.

Big doin's this weekend, I'm so proud of her.

Made a push before the muscle biopsy which went well by the way. Anyway, I wired things up temporarily and tested the electric fuel pump (that worked, dry), tested the starter solenoid (started engaged the flywheel correctly) and then figured what the heck I'd try the starter. I pulled the spark plugs, squirted some oil down the cylinders and gave it a crank. Everything turned over as it should, no weird noises. I also did the cut on the headers and installed the baffles.

Once my arm is better I've got a few things to do and I can try to start it. Very cool!

Just got back from South Carolina, took my daughter down to Clemson for orientation. Had a great time and celebrated my oldest son's Master's in Mechanical Engineering. At the party my wife and I schooled my middle son in beer pong winning 4-5 games however the next day didn't feel like such a victory.

Hoping to get the last few things temporarily setup so I can try and test start the engine this weekend. Fingers crossed.

A couple of pictures...

I added a 1" spacer between the brake and clutch pedals


Here is the oil cooler, mounted on the drivers side torsion bar housing


The engine with high temp oil lines almost ready to go, also the slash cut pipes and baffles installed.


June 22, 2010
Evolyn is ALIVE! I pressure tested the carb float against the fuel pump and everything looked good so I gave her a try. The first start had backfiring so I had to switch the crank sensor wires, but the next start ran smooth. Made some initial adjustments to get the idle up and it runs real good. In the garage (one door open) it is pretty loud, but I'm thinking it won't be so bad once I get it outside. Hoping for a test ride this weekend.

June 23, 2010
First time out...

Needs some tweaks, Bowden Tube adjustment and bracket (bad clutch chatter going up the driveway in first gear) Steering stops to prevent turning too far and some engine tuning (too rich) All in all, a successful test drive

Thought I would closeout the mechanical part of the build with a short video of the initial test. So here they are...

on the road video by evolyn80 - Photobucket

on the road video by evolyn80 - Photobucket

Up the driveway, you can see the clutch chatter issue. Turned out to be bowden tube adjustment.

finish video by evolyn80 - Photobucket

finish video by evolyn80 - Photobucket

Next, the body build...

[EVOlyn]

It is the end of August 2010, so we'll call it September. I've searched the Internet, read books and talked with a few vendors, not to mention the help I've gotten here. After much thought, I've decided the only way I'm going to be happy is to build my own body. Right now the plan is to use epoxy over polystyrene foam like the blue 4x8 sheets you can get at Lowe's and Home Depot. Polyester resin dissolves this kind of foam, hence the epoxy. From the books, looks like the best way to achieve a symmetrical body is to use wood ribs, glue the foam in between them, then sand to the wood shape. Once complete, cover with epoxy resin and fiberglass, then sand and sand and sand until it is smooth.

Here is a shot of the side panels. They will run along the steel frame at the base of the pan, between the wheels. As you can see from their shape, nothing is going to be straight on this, everything is going to be curved. The wood is poplar, 'the cheapest hardwood' since hardwood is supposed to have similar expansion characteristics as fiberglass.

Next, here are the inserts I'm using to attache the wood frame to the steel frame. They are 1/4 20 threaded internally and fit quite snugly. I think they will provide adequate connection.


more later...