72 Combat Proddy Build

Re: 72 Combat Proddy Build- It begins...

72 Combat Proddy Build

I borrowed the jack from the BMW. It's the slickest, lightest jack I've even seen and it easily lifts the 2 ton car. I tried to pull the engine bolts to get the clearance I needed to get a drill to the centerstand holes I needed to enlarge. In the end I pulled the front iso bolt. I also needed to remove the headsteady to get the clearance I needed.

72 Combat Proddy Build

I have an extra long 1/2in drill. I used this and then finished the hole with a 9/16in step drill. It worked.

72 Combat Proddy Build

Initial fitting.

72 Combat Proddy Build

If you don't have one of these spring pullers run, don't walk to Harbor Freight and get one. It's saved me a million times. About $5. It popped on the centerstand spring on with no drama. I tried the washer trick but the puller worked flawlessly.

72 Combat Proddy Build

72 Combat Proddy Build

72 Combat Proddy Build

Up on the sidestand. One less thing to do.

Still need to replace the Helicoil in one hole in the crankcase that hold on chaincase. Hopefully this weekend. And then I need the spacer behind the clutch basket before finally setting the belt and closing up the chaincase.
 
Re: 72 Combat Proddy Build- It begins...

Helicoil replaced. While I'm waiting for the clutch spacer I'll make sure the chaincase is shimmed correctly.

Installed the pushrod by myself. Smeared it with grease, that should stop the gearbox oil from migrating.

Also got a clutch cable adjuster. Also managed to install that myself. :mrgreen:
 
Re: 72 Combat Proddy Build- It begins...

Those Dave Comeau clutch rod seals are the right stuff.
 
Re: 72 Combat Proddy Build- It begins...

grandpaul said:
Those Dave Comeau clutch rod seals are the right stuff.
Click to expand...

Yeah, but I wanted to see if the grease trick works.
 
Re: 72 Combat Proddy Build- It begins...

Threw some parts on it to see what it's going to look like.
72 Combat Proddy Build


72 Combat Proddy Build

Then I Photoshopped the rest. If only it was that easy... :roll:

My to-do list:

Need spacer behind clutch
Clutch nut is at the local shop. Just need to pick it up when the spacer comes in.
Then gearbox is set and belt drive final install. And alternator. Rear chain.
Carbs are bare. Need everything. Will order from Amal at some point.
Throttle cables.
Headlight rim. Headlight is coming from BrianK (hopefully Tuesday).
Fuel taps. Fuel lines.
Front brake disk needs skimmed. Pistons installed and bled.

Bike should fire at that point. Might even make it down the alley.

My goal now is to have a running (maybe not street legal) bike for the All British Field Meet on Labor Day weekend.
 
Re: 72 Combat Proddy Build- It begins...

Jeandr said:
Looking good Dave.

Jean
Click to expand...

Keep in mind that a lot of those parts are just sitting on there. Chaincase is empty, tank and seat aren't mounted... etc.
 
Re: 72 Combat Proddy Build- It begins...

swooshdave said:
Jeandr said:
Looking good Dave.

Jean
Click to expand...

Keep in mind that a lot of those parts are just sitting on there. Chaincase is empty, tank and seat aren't mounted... etc.
Click to expand...

I know, just saying I like the general looks and the direction you have taken with the bike.

Jean
 
Re: 72 Combat Proddy Build- It begins...

swooshdave said:
Jeandr said:
Looking good Dave.

Jean
Click to expand...

Keep in mind that a lot of those parts are just sitting on there. Chaincase is empty, tank and seat aren't mounted... etc.
Click to expand...


Looking very good but the handle bars don't fit with the proddy bike image and won't feel right with rear-sets. Are you going to change them eventually?
 
Re: 72 Combat Proddy Build- It begins...

JAYMAC said:
swooshdave said:
Jeandr said:
Looking good Dave.

Jean
Click to expand...

Keep in mind that a lot of those parts are just sitting on there. Chaincase is empty, tank and seat aren't mounted... etc.
Click to expand...


Looking very good but the handle bars don't fit with the proddy bike image and won't feel right with rear-sets. Are you going to change them eventually?
Click to expand...

I bought some Honda MX bars for my Pursang but discovered the old dirt bikes like wide bars for leverage. The Honda ones were too narrow. They are on the bike until I can bother to get some other ones. I'll probably use Euro/Superbike bars for a while. I'll also be using the stock tank and seat as I see fit.

The fairing is back in NC. Not sure when I'll get it and not really in a big hurry. It's been a while since I rode on the street so I'll stick with a more standard config for now.
 
Re: 72 Combat Proddy Build- It begins...

How about this one, it's in your palette of colors :lol:

72 Combat Proddy Build


Jean (mark me biased, but I lke the green one)
 
Re: 72 Combat Proddy Build- It begins...

Jeandr said:
How about this one, it's in your palette of colors :lol:

Jean (mark me biased, but I lke the green one)
Click to expand...

Wrong seat, front end, etc...
 
Re: 72 Combat Proddy Build- It begins...

Needed to fit the seat. Yes, it was made like crap but really, I wasn't surprised and didn't bitch about it.

72 Combat Proddy Build

72 Combat Proddy Build

The glue had come undone. May have been from sitting in the NC heat all those years.

72 Combat Proddy Build

No problem, I added some more rivets and it looks much better. Picture is pre-additional rivets...

72 Combat Proddy Build

This is how it came from the vendor. Someone drilled two holes and neither one was right. I took a Dremel to it and now it's better. It still has a bow to it but that will straighten out once I get my fat ass on it for a while.

Fat-ass fettling, I call it.
 
Re: 72 Combat Proddy Build- It begins...

Dave,
now there's a new term for fitting :shock:
Starting to look like a motorcycle now.
Taking your time will pay dividends.
I didn't rush mine and it looks like I got it right.
I think when your too excited to bring it home and quickly change the fluids and take a maiden voyage that's when you
realize all that's wrong with the bike.
I did that exact thing in 1982 with a 73 Bonneville.
Got so excited before I sorted out everything I didn't even make it around the block before pushing.
Pushing sucks. At my age now pushing is a heart attack :shock:
Marshal
 
Re: 72 Combat Proddy Build- It begins...

As posted elsewhere, I stripped the many layers of paint from the side covers.

2010-most-improved-winner-t6968.html

72 Combat Proddy Build

I'm currently fiberglassing up some holes and a notch put in by a previous owner. Then I'll paint the insides black. The outsides will get painted when the tanks are ready.

72 Combat Proddy Build

Picked up a new oil filter. I have no idea what the old one was but it was pretty dried up looking. The new one is for a Ducati or Harley and is nice and chromey, so you have to think it's for a Harley. About $10 from NAPA.

Some of the vendors are at Lumby so I'll have to wait some more to place the orders. Currently on the way are parts for the Amals and some valve cover gaskets from Rocky Point. Along with the rear axle adjusters.

Probably one of the more underwhelming updates. Hopefully the next one will be better.
 
Re: 72 Combat Proddy Build- It begins...

Hey Dave, looking good. Are them knobbies a little squirrely.
72 Combat Proddy Build
 
Re: 72 Combat Proddy Build- It begins...

pvisseriii said:
Hey Dave, looking good. Are them knobbies a little squirrely.
Click to expand...

Knobbies? Them is genuine "Made in Ireland" K81 TT100 Dunlops!

Parts are rolling in. Hope to start applying them soon.
 
Re: 72 Combat Proddy Build- It begins...

72 Combat Proddy Build


Fresh from England is a pile of new Amal parts. Complete kits that will replace just about everything. Includes the new floats. Hope to have the carbs done tonite.
 
Re: 72 Combat Proddy Build- It begins...

72 Combat Proddy Build


They need to come off again to check flatness, seal up the choke cable holes and such. I should have the cables here no later than Saturday.

Then figure out the fuel lines. I really prefer Tygon (you can see some used on the balance tubes) as it's chemical and UV resistant. And flexible. And transparent.

Once the throttle cables are on I'll start working on getting the tank mounting sorted.
 
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