I also had 1/2” longer locating dowels made; the Jampot article indicated the final spacing-out of the outer cover could be very narrow, but I figured I could cut these back down myself easily if needed.
[ATTACH=full]74320[/ATTACH]IMG_20191011_153957000 by Mick Doul, on Flickr
When the kit arrived, it contained the pulley, clutch, belt, and spacer for the alternator rotor.
[ATTACH=full]74321[/ATTACH]IMG_20190922_134156845 by Mick Doul, on Flickr
Unfortunately, Bob sent a splined pulley suitable for some Matchless engine, and not the Atlas tapered arrangement. He was quick with the replacement pulley and spacer, and I was able to get underway.
I found the spacer didn’t like to work with the Woorduff key, but I simply trimmed a little off and it fit nicely.
[ATTACH=full]74322[/ATTACH]IMG_20191008_141827015 by Mick Doul, on Flickr
[ATTACH=full]74323[/ATTACH]IMG_20191008_142721057 by Mick Doul, on Flickr
[ATTACH=full]74324[/ATTACH]IMG_20191008_142956305 by Mick Doul, on Flickr
Checked alignment of the belt path before putting the inner back on
[ATTACH=full]74325[/ATTACH]IMG_20191004_173233733_HDR by Mick Doul, on Flickr
[ATTACH=full]74326[/ATTACH]IMG_20191004_173223101_HDR by Mick Doul, on Flickr
Mocked up and checked tension; loose with an easy twist to 90 degrees cold
[ATTACH=full]74327[/ATTACH]IMG_20191008_125905035 by Mick Doul, on Flickr
And got it running as a test. You can see the clutch adjust screw is waaay out; I think I had an extra ball in the pushrod at this point, as I was dealing with some disconcerting clutch slip.
[ATTACH=full]74328[/ATTACH]IMG_20191008_153253935 by Mick Doul, on Flickr
So after all this, the clutch really had some tremendous slip. After some flailing and thinking, I realized the clutch pressure plate was lightly riding on the transmission shaft. To fix it, I ground out just a tiny bit of metal from the center of the pressure plate which freed it to apply full pressure to the clutch pack. After talking with Bob, he said that with the “norton-type extended mainshaft,” this was always an issue, and he recommended taking 2mm off the mainshaft itself or adding another steel disc to the clutch. I may consider this if the clutch slips anymore in use after heating up fully, but for now my fix is working.
