Reassembly Updates

So I finally got all the parts in that I need to repair the damaged timing side of the motor: Idler gear, reduction pin, flywheel gear, and starter clutch. I also decided to just replace the entire side cover so I didn't have to worry about that Bondo'ed retaining lip. A fellow DMF member offered me a screaming price on the cover so it was hard to pass up. All in all, after selling that nice Nichols flywheel that I couldn't use, I came out ridiculously cheap for the parts. All included, I spent $59 on the replacement parts.

Earl and I took some more material off the flywheel and drilled a balancing hole, shown here:



After getting the new side cover in the mail, I realized I wouldn't be okay with having two side covers  of different color, so I decided to prep and paint them. While I was cleaning the clutch-side cover, I ran my index finger along a very sharp lip, and got insta-blood:



Truly blood, sweat, and tears poured into getting this thing ready.

Before I started painting I needed to make a small cover and gasket for a sensor hole in the new cover (my old one didn't have the hole). Started off with a sheet of aluminum, cut out a rectangle, then used my Dremel, grinding wheel, and file to shape the rest of it. A piece was cut out of stock gasket material in the shape of the cover.







Here are the covers before paint, showing why I wanted to paint in the first place:



Here they are after the first, light coat of VHT engine paint. Yes, I used some duct tape for masking tape. I made the mistake of buying Ace Hardware brand painters tape and it was absolutely terrible. Had to make due with what I had at that point:



Three coats in:



After 30 minutes of curing at 200 degrees in the oven... I don't think Laura was too happy about motorcycle parts baking in her kitchen...



Finally a picture on the bike. I'm still waiting on the gasket for the right side cover to come in: