Chip's '72 Combat project

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AH! Comfort at last.

It only took a couple of hours to clean up and stash all the extra stuff that had been piling up in my office over the years, I didn't even need to ditch the spare desk.

Now I can detail the bike in air conditioned comfort...

Chip's '72 Combat project
 
Here's the new chainguard that came with my Combat, I'm putting it on your bike as a pennance for going overtime-

Chip's '72 Combat project


Fender/Tail and tail light all done. I happened to have a like-new 5-hole cannon plug for the wires so it's nice and tidy under the seat. I also
grafted in color coded wiring extensions so you can remove the seat without un-wiring it for service, then just tuck the pigtail into the hidden
cubby in the tail, no mess, no fuss.

Chip's '72 Combat project
 
Got the remaining electrical wiring up front including instrument lights, headlight jack for modern headlight, warning lights for
hi-beam & alternator, and front brake light switch. I had some more new/used electrical stuff come in last week, so I was
able to sort all the proper color-coded segments with the large bullet connectors and spades already installed. Also rounded
up much nicer F/F rubber-covered bullet lugs to join everything up nice and tidy. Once I get the instruments and idiot lights
properly mounted in the dash, I'll snap a photo.

Meanwhile, I also drilled the timing case for the breather and ran the vent line, just need to locate a proper fitting nut for the inside
and then re-install the timing chest cover; for now, the fitting is sealed in place with JB Weld.

The sterile operating theatre-

Chip's '72 Combat project


The recovering patient-

Chip's '72 Combat project
 
Good progress today, besides the timing chest breather-

I found a great use for cheesy beer koozies, they make perfect instrument sleeves for mounting in fiberglass dashboard panels
(they are also great for storing new or rebuilt instruments)

Chip's '72 Combat project


Fabricated two retainer brackets for the underside and all of it nipped up quite nicely. I've still got a bit of housekeeping to do under
the dash to have it looking nice and neat

Chip's '72 Combat project


I couldn't find a Blue bezel, so it's going to be Red for alternator low output, and Amber for high beam; just need to get two tiny
idiot light bulbs for the dash

Chip's '72 Combat project


Windscreen carefully drilled and installed, headlight installed and tested

Chip's '72 Combat project


CRG bar-end mirrors reworked so that both face "up", with all 4 allen screws facing up; they have to come off to install the hand grips

Chip's '72 Combat project


Lean and lanky

Chip's '72 Combat project
 
Breather all done-

Chip's '72 Combat project


I will nip up the timing chest and then just the following tidbits remain 'till closing time:

Center stand

Tach cable drive pin and connect cable

Gas tank & seat rubber cushions and hold-down hardware

Install sidecovers (need to fab up a small loop bracket for the left side)

(2) Idiot light bulbs

Rear brake pedal grease nipple bolt

Shake-down runs & cleanup / detailing.
 
The last of the punchlist is complete except for pulling a couple of idiot light bulbs out of my Trident and popping them in the high beam
and alternator warning light sockets.

These are not the final high-res photos, I still need to ride over to the painter's shop and have them buff everything out as soon as
I get the call from Keyboard that they'll pick up the next day (should be on 8/6 or 8/7).

Chip's '72 Combat project


Chip's '72 Combat project


Here you go, TWINS! (Fraternal)

Chip's '72 Combat project
 
Timing is EVERYTHING.

I had the misfortune of slipping in the mud while hiking around our fishing pond to get to a better spot on Saturday afternoon. I AT LEAST sprained my right knee, maybe worse. I can't kickstart a bike for at least a week, especially a high compression Combat!

Boy, am I ever glad the de-bugging is done and the bike is trusty. I'm pressuring the guy that owes me those starter motors to get them down here to me on FedEx so I can get my roller starter going, I want to keep doing daily rides "just in case". Still, if for any reason the bike dies on me away from my shop, I'll need to call in my buddy to bring me my trailer.

Dodged a bullet there...
 
Well, 7-1/2 months after work began, work is done.

The Keyboard truck arrives tomorrow morning, and all the details are done.

Out for one last blast on the loop, the speedo fluttered all the way up through the gears, then settled in nice and stable right at 80,
I should have noted the RPMs...

Anyway, "Before & After" shots:

Chip's '72 Combat project
 
Very nice work, Paul!! I have enjoyed seeing the build thru pictures.

Out of curiosity, how did the budget work out? Were you able to keep it close to the $10K estimate?
 
Very close indeed. Chip added a couple of things, but thankfully there were no suprises. I tossed in a few freebies at the end as pennance for taking an extra month and a half.
 
Just wanted to provide an update on the project. I spoke with the folks at Keyboard (keyboardmotorcycleshipping.com) on Friday and the bike is scheduled for delivery on Tuesday morning...the exact day Tropical Storm Fay is supposed to be rolling through town. After waiting 22 years it appears there's going to be some genuine excitement as she's rolled off the truck!! Unfortunately, it'll be straight to the garage until the weather clears up. :wink:

I'll post a ride report and photos after the first week or so. Thanks to all who followed the project and so kindly offered comments or advise. Cheers!!

Chip
 
Just realized that this thread sort of "disappeared" without a report on the bike's arrival.

Rather than trying to hide bad news, I prefer putting it right up front - the bike arrived with issues that needed dealing with before Chip could enjoy riding it. They included carburation and oil leak situations which could not be corrected in the driveway, so I advised him to take it to a nearby Norton shop for servicing.

As with all of my clients, I leave a "warranty retainer" at the end of the project, to deal with exactly these types of issues that crop up after the bike is returned.

As I type this, the Combat is being looked after for wet sumping, and the carburation is sorted. It looks like I may have gone further than recommended on re-facing the oil pump plate, causing excessive weepage back into the crankcase sump. The float adjustment issue was just flat out wierd.

Anyway, we should be getting a report before the end of the year.

I need to say, Chip is the most patient client I have EVER met, in 35 years of at least half a dozen different businesses.
 
GrandPaul, I just wanted to say thanks for documenting this build. It has been an education to someone like me who is new to Norton's and a great vicarious learning experience.

I also really appreciate your honesty in not trying to hide the "bad news" and the issues that occured after delivery. To see that these kinds of things occur even to the most experienced builders gives us noobies some comfort when things don't always go as we planned.


GB.
 
Thanx to all who have commented.

Don't even ask about the time I failed to drive the sludge trap all the way in on a client's Triumph Bonneville crank. JUST 1/4" SHORT!!! Tiny mistake = BIG ouch.

Live and learn. At least the client is still happy and that project has sparked a request for an identical '69 Bonnie to be built next year.
 
GOOD NEWS!

Chip went to check on the status of the bike this past weekend, (it's been a slow go, but progress is now being made).

Oil leaks are cured, carburation is cured for the most part (brand new Amal had a loose float needle seat from what I gather).

Last problem remaining is there seems to be a looseness in the swingarm. This one has me flummoxed, ALL NEW bushings, iso rubbers, harware, etc. NO POWDERCOAT on any chassis/cradle/engine/trany/iso mating surfaces WHATSOEVER. Axle totally tight. How the rear end can have looseness in it is totally beyond my understanding at this point.

Anyway, Chip had it up near the ton, out and about, and he says it feels great. Hopefully it will be back in his garage next weekend, never again to leave except for long, fun, uneventful rides.
 
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