Seeing a wonderful shade of Red!!!!

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You say the bottom motor mount holes are also larger? Did you have to drill out your bottom motor mount plate? I will be/plan to use a 193R in my Diablo.

Sorry Mark. I forgot to reply to your question. Yes, the 191 has 1/2" threads in the motor base instead of the 3/8" that the original 190 has. To make the bottom motor mount work, I just drilled out the four holes larger. It fit great.

Bruce

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A new reproduced Exhaust Manifold is to be used. Shown in the picture below are the manifold, an NOS flex pipe, a stainless steel exhaust pipe and clamps.

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Sometimes, a NOS part is not the best. In this case, I just could not bring myself to install the steel flex pipe. In a short period of time, the steel flex pipe will rust. For this Diablo, only a stainless flex pipe will do.

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Put the hood on and the front plastic nose cone along with the headlights. The headlights are NOS and the nose cone is reproduced. Together, they make a pretty nice pair.

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That is a 500 restoration going on there in the back. Poor thing is pouting cause the 503 is getting all the attention.

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[Go Go Diablo]

The wiring is complete.

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Overall, nothing special. Just all new wires, the key switch with harness and some of that black hollow conduit.

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The new battery is installed with new cables. The top battery hold down is one of the reproduced ones we recently had made. It fits perfect.

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Gotta love those 503 headlights. That new starter hums like a million bucks too

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A happened to have a NOS HR3A carb for this bad boy. I struggled a bit wondering if I should pull it apart and check it over or just install it as is. I voted for the second option. It's new right? It should work great.

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A new reproduced heat shield is under the carb. Also a new reproduced tri-pod carb cover installed.

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New fuel lines and fuel filter.

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Starting some work on the Ski Seater. The skis for this NOS Diablo of course have to be NOS skis. Original NOS skis are maple and painted black. They typically come without holes or the steel runners under them.

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For all my skis, I glue a wear strip of Durasurf onto the bottom. The UHMW 1/8" thick plastic does several things.
- Protects the bottom of the skis from rocks, trees, sticks, nails, ice, gravel - need I go on
- Protects the bare wood (because of the above) from soaking up moisture which make them warp. Even sitting on the concrete floor in the garage will send moisture into the skis and make them warp.
- Provides a super smooth finish to glide across the snow. Almost like adding a few more HP to the motor.

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The Durasurf is specially treated on one side to accept the gluing process. The Alderite Glue is very expensive, so it's weighed out carefully and spread on the bare ski evenly. Once on, it stays soft for plenty of time to set the wear strip in place and weight it down appropriately. Once dry, the adhesive remains pliable and bends with the skis.

[Go Go Diablo]

On an NOS Diablo, you just have to put a new Nacelle Cover. Now that is pretty.

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The skis are done. They have the UHMW wear strip attached along with new Half Oval runners riveted to the skis.

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[Go Go Diablo]

After a little time away from the NOS Diablo rebuild due to some other Diablo priorities, we are back at it.

First off, had to put those wonderful Positive Post terminal protectors on. Those things are awesome and offer much protection from the wild swing of the wrench

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Next is an NOS Brake Caliper Assembly with new shoes. Not sure what was more interesting - the caliper or the paper it was wrapped in. Straight from the Ozaukee Press dated Thursday, November 10, 1966. Ozaukee County is where Port Washington, Wisconsin is. If you know Diablos, you know Port Washington which is where the Bolens Factory was. Anyone want to know the Port High Football Statistics for 1966?

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The Primary Clutch was especially educational on this Diablo. The original Hirth motor in a Diablo is a 190R. A far more common motor is the 191R which this NOS motor is. The only difference is the slightly larger base mounting holes and the larger output tapered shaft. The 190R has a 25mm shaft and the 191R has a 30mm shaft.

No problem right? There are lots of those 30mm Salsbury Clutches around right. The problem is that a 30mm clutch does not mount properly on the 191R motor to work in a Diablo. When putting the 30mm clutch on, it slides up the taper within a fraction of an inch away from the motor housing. With the starter mounted under the motor, the clutch rubs against one of the mount bolts. In addition, the clutch does not line up properly with the secondary clutch. I scratched my head for a while wondering why this was happening.

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Then it dawned on me. The 190R taper is a 25mm and if you measure the bore of an original Diablo clutch, it's 24mm. The smaller bore of the clutch places the position of the clutch about 3/8" away from the motor housing and lines the clutch up with the Secondary Clutch. What I needed was a Salsbury Clutch with a 29mm bore.

So I searched the internet and talked with a few people about such a clutch or a possible tapered bushing to install in the 30mm clutch. No luck. My next step would have been to have a small bored clutch machined out and was not sure that would even work. About this time, I went to the A1 Swap Meet in Lower Michigan and my last purchase of the day on the way to my truck was a Hirth 293 motor and it had a clutch on it. It was cheap and I figured I could save a part or two.

When I got home and took the clutch off, low and behold, there was a 29mm bore.

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