Final Push...

Over the last couple months my step-mother, Ann, has distributed some of Dad's things.  I have received several karting oriented pieces, some which I have already displayed in an earlier post.  Recently, she gave me more Indy Kart Club shirts and assorted other things.

Here I am wearing Dad's IKC shirt from the early '70s. The fun thing about these is they are really bowling shirts! They even have a bowling pin logo on the front pocket.  Dad's name is embroidered on the front and the club name on the back.  I reckon it was a low-cost way to personalize the shirts.  

The shirts arrived just in time for me to wear one to a sock-hop.  That's Pam and I in our costumes.  Several people told me the shirt was perfect.

Now that we know the shirts fit, they can be used by a pit crew!

It's been a while since my last kart-work-day.  I had my to-do list and tried to work my way down it.

I started with the final collars holding the swing mount in place on the rear axle.  Then on to aligning the sprockets....which means putting on the clutch.

I pulled the chain out of the motor oil which it has been for a rear.  Here's the oil draining off.

Oilers are now illegal so it becomes a sprocket holder.

I had to remember how chains go back together.

OK... it actually means the ASSEMBLY of the clutch.  The clutch fits on the protruding camshaft.

Here is the clutch drum in place with the half-moon key in the camshaft. 

Here is the a detail view of the clutch housing in place with the half-moon key in the camshaft. 

 Then the gut go in.. the hub and shoes. Next is the clutch cover which is held on with the ring that is behind the drum...  Oh.. it is not there.  So I get to practice taking the drum off.

 OK, that's better... with ring in place.

 Here is the whole clutch: (l to r) ring, drum, cover plate, pulley

 Here it is dry fitted together before tightening the hex bolts.

Crud!!  The ring must be oriented correctly.  50/50 chance and I picked wrong.  The fully flat side needed to be in-board, like this.  So I get to practice taking the apart... again.

  NOT like this.

  Finally, here is the clutch with the cover on.  Notice it is an open cover.

 With the starter pulley

Next would be aligning the sprockets, then tightening the engine mount...tightly!!!

Always remember to use a good safety pin on the chain.

 Allow about 1/2" slack in the chain.

With that done, I took a look at the fuel line.  I cut it to length with little extra.  I'm not sure if there is a need of  a loop (probably... with the decisions I have made).  There is enough fuel line left over.

Here is the fuel turn-off on the tank.  I put some gasoline in but no flow, so I took it apart and used a wooden swab on it.  Yep, a bunch of crud and old, dry fuel.  I let the gas run out to clean it up more.

 The last piece on the engine was the exhaust. It has been in one piece but to put back on, I had to take it apart.

I could not get an allen wrench to on of the manifold hex bolts, so had to grind down another allen wrench to fit.  That's about 3-4 allens I have modified.  I just can't remember how Dad and I took it off.

 The advise Greg Wright gave was to have the kart all together to start it the first time.  Never start it on the bench.. it needs to "pull" against something or it could accelerate and go BOOOOMMM! That means TIRES!  The old inner-tubes have held air for two months.  They started with 20lbs and only dropped to 12-15lbs.

Here is the front tire with safety wire instead of a cotter pin.  But they had cotter pins!  I looked at the photos from before the rebuild and found that I put the tires on wrong.  I thought the tube stem would go on the outside.  NO! the stems go inside.. notice the recessed area around the nut.

 But the rear tires went on just fine. Orientation on those is easy.

So here it is. OHHH so close to being done.

 Here is my new to-do list:

To-Do List

Brake safety tether (KISS)  3' 1/8" CABLE  / 2 CABLE CLAMPS /A LOC-TITE

3GAL GAS CAN

CONTACT HOOSIER TIRE FOR RECOMMENDATIONS

Replace pin with bolt with locking nut/cotter pin

Buy gasoline (which grade?)  sunoco or shell premium (called Hi-test in past)

Mix gasoline and oil  (20:1 or 16:1) (10-12oz Burris castor:1gal gas)  Shell & Stihl oil (add stabilizer for end of day flush)

Clutch oil --  old Hartman oil should work

Review first start procedure ( 1-2oz. fuel mix in carb and .5-1oz through plug hole to cylinder):  idle for 10 minutes until warmed up on horses/stand; repeat 3 times; re-torque head bolts)

Remove engine swing mount to fix rubber gasket

Place fixed swing mount

Place locking collar on Swing mount on axle (use punch to tighten then set screw)

Place engine on swing mount

Tighten engine mounting bolts to torque limit (loc-tite)  CHECK

Attach clutch to PTO side (half-moon key, clutch housing and ring, shoes, gasket, cover, tighten pulley         bolt, hex bolts with loc-tite, fill with oil) MORE WEIGHT= LESS SLIP

Align sprocket/oiler to drive sprocket (oiler not allowed.  put lube on sprocket)

Fill oiler at track(~70weight gear oil)(holds enough for one hour of racing)

Connect throttle cable to carb; attach to frame with zip-ties

Connect brake tubing to frame with zip-ties

Put on pipe (torque wrench)

Battery to starter and test (Check correct direction!!)

New belt?

Put on fuel line ( need a loop? PROBABLY)

Add gas/oil mix

Open the fuel valve

Set carb needles per manual before start

After start, set carb needles per manual

Buy new tires (Dunlop SL4) and tubes

SAND BLAST WHEELS???

Balance tires

Put on tires SWITCH FRONT TIMES SO COTTER PINS CAN WORK

Balance frame with a scale under each tire (what then?  tire pressure?   frame?)

Put temp gauge on spark plug (gauge is in helmet bag.  where is the plug end?)

Buy strong rod bolts (Bonbright)

Set clutch at high rpm

Inventory all kart parts and tools

New boxes for parts

catalog what tools are needed

table for pits

tent for pits (UMMM... BREAKING DESTRY TENT DID THAT)

Start wiki of info

EAR PLUGS



and much much more

Here is the IKF book Dad still had.  Inside were these items: 

His 1972-3 enduro licenses.  Each race was dated and signed by an official. Most here are by Homer Adams... I think the registration ladies actually signed most. :-)

Here is an advertisement for the McCulloch engines that were the leading engines of the time.  Within about 5 years Yamaha was more and more popular.

And the IKF sticker and patch.  IKF is now solely west of the Mississippi, and the WKA sanctions east of the Mississippi.