Yellow Fever

These posts document restoration experiences of our members
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randys444
Posts:95
Joined:Fri Apr 22, 2016 6:43 pm
Finished jackshaft assembly

Post by randys444 » Sat Dec 03, 2016 1:00 pm

This assembly is pretty much all brand new. New bearings, sprocket, brake disc,spacers,jackshaft , woodrufff key, and rebored salsbury clutch. The rest of the clutch was in good shape and the aluminum casting was nice. Cleaning and new paint on clutch.
Attachments
10302016201417.jpg
Finished assembly. Many hours of work on this. Happy this part is finished.
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103020162029.jpg
Everything turns and fits beautifully.
103020162029.jpg (208.29KiB)Viewed 8041 times
Bring on the snow

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Barrie2777
Posts:1547
Joined:Tue Mar 04, 2008 9:17 pm
Location:Arundel Quebec

Re: Yellow Fever

Post by Barrie2777 » Sat Dec 03, 2016 9:23 pm

All I can say is WOW!!

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fap67
Posts:223
Joined:Tue Oct 06, 2009 5:02 pm

Re: Yellow Fever

Post by fap67 » Sun Dec 04, 2016 10:48 am

Excellent work Randy. Do you you know how the splines were machined? For example, did he use a shaper and grind a tool to the correct profile, or a milling machine with a pre-made cutter that was the correct profile or some other method? I'm a very, very amateur machinist and interested in how things like those splines are cut.

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randys444
Posts:95
Joined:Fri Apr 22, 2016 6:43 pm

cutting splines

Post by randys444 » Sun Dec 04, 2016 10:39 pm

The machine used was a gear hobbing machine. It has special cutters that match the shape needed to be cut. I haven't personaly seen the machine yet. After I finish my 444 I want to check it out myself. I have been a machinist for 30yrs and wouldn't attempt cutting them any other way. This old boy doesn't let to many people in his shop, but he is someone I know from a previous job and we are getting to be good friends. If I can take some pictures of these machines eventually, I will post them for you. I do know he has a large inventory of cutters which he tells me are very costly. Luckily he had the one for the jackshaft. I did make up 6 extra shafts, but I'm going to run this 1st one in my 444 to test it out before I would let any others go.
Bring on the snow

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fap67
Posts:223
Joined:Tue Oct 06, 2009 5:02 pm

Re: Yellow Fever

Post by fap67 » Mon Dec 05, 2016 7:34 pm

Thanks for the info. I always like seeing how different people go about making or repairing parts for these machines.

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randys444
Posts:95
Joined:Fri Apr 22, 2016 6:43 pm

Carburetor mounting plate

Post by randys444 » Thu Dec 15, 2016 10:30 pm

I had to make a new carb. mounting plate for my brothers 1965 hus-ski 600. It was cracked so we decided it was time for a new one. He is Mark (1965 Hus-ski) on the forum.
I make all my parts with a manual Bridgeport Mill adapted with a new digital readout and powerfeed. I also use a manual lathe.
Attachments
082017103855.jpg
Here is a picture of the mounting plate from my brothers 600. It was repaired with a plate along the side.
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The one on the left is the original from my 444 I used for the pattern. The 2 on right are the new ones I machined.
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The material used was Garolite or sometimes called Phenolic. This particular type can withstand 265 degrees F.
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Last edited by randys444 on Sun Jan 08, 2017 12:05 pm, edited 3 times in total.
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randys444
Posts:95
Joined:Fri Apr 22, 2016 6:43 pm

Seater

Post by randys444 » Thu Dec 15, 2016 10:59 pm

Getting my parts together for the seater. It was in rough shape. The frame was good and I saved the backrest arms. Had to make new ski mounting brackets, skis, coupler piece to ball joint, seat and backrest. I bought the toe clips from Barrie and the ski runners from Bruce. Also got lucky and found a new taillight assembly,my old one had many rust holes completely thru it.
I made a pattern for the seat and backrest from my brothers 600. The skis a friend made for me, he is an awesome woodworker and steamed the maple skis plus laminating UHMW to the bottom.
Attachments
11142016204257.jpg
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1114201620441.jpg
These dimensions were also taken from the 600 seater.
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The seat and backrest are out for upholstery right now.
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randys444
Posts:95
Joined:Fri Apr 22, 2016 6:43 pm

Finishing hood

Post by randys444 » Thu Dec 15, 2016 11:18 pm

Been working a long couple months on the metalwork for the frame/chassis assembly.Finally finishing up that with the handlebars,seater and hood.
Here are some pictures of the hood.
Attachments
11142016203540.jpg
I didn't have an original headlight ring so I made one. It's not 100% original but looks nice. The hood scoop metal was made in one piece. It took about 5hrs to shape and weld in.
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The expanded metal is a little larger than stock but I thought it looked nice and was easier to weld in than the lighter material.
11142016203413.jpg (197.93KiB)Viewed 7975 times
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randys444
Posts:95
Joined:Fri Apr 22, 2016 6:43 pm

Finally off to paint

Post by randys444 » Thu Dec 15, 2016 11:24 pm

Feels good to finally be ready for paint. Many hrs as you all know.
Attachments
11142016203019.jpg
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1114201620315.jpg (144.96KiB)Viewed 7975 times
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randys444
Posts:95
Joined:Fri Apr 22, 2016 6:43 pm

Finally off to paint

Post by randys444 » Thu Dec 15, 2016 11:28 pm

I'm not a painter so I have a local shop helping me out.
Attachments
11142016202331 (2).jpg
Paint and body shop is going to take care of the wrinkles and dents for me.
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11142016202435.jpg
Should be yellow and black in a few days.
11142016202435.jpg (120.96KiB)Viewed 7975 times
Bring on the snow

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