400 restoration project

[Barrie2777]

On an original cone muffler, the inner perforated pipe is supported at the tip exhaust point. Assuming more vibration and stresses for this bigger engine, I have welded in a support for the innermost end of the exhaust pipe.

[Barrie2777]

Just a little more advancement on the muffler. The muffler on the left is for the 252 cc while the one on the right is an original 148 cc muffler. Before I do the final welding on the muffler I would like to do a test fit with the new support springs. They may not be in for another week.....

[Barrie2777]

I'm still waiting for the support springs to come back from heat treating.

[Barrie2777]

At last these support springs have arrived and this project which had ground to a halt, can now be completed (I hope).

[Barrie2777]

This muffler has been off and on two dozen times so I could get the correct placement of the exhaust hole in relation to the hole in the side wall.

[Barrie2777]

The choke cable comes with a knob which is not correct for originality so I change it with the correct knob. Just break the new one off (usually plastic), file some grooves in the shaft to provide a bite for the epoxy, then epoxy on the replacement knob. This is a 5 minute fix but WOW! so much better.

[Barrie2777]

The choke cable is secured with a choke cable holder which is secured to the engine though that often unused threaded hole just in front of the carb. Before I commit to securing the choke to the carb, I fully extract the choke wire and coat it with anti seize material for brakes. This should eliminate those freeze ups in mid winter. I find that oil or grease also works but must be redone on a regular basis. Be sure to avoid sharp bends while installing the choke cable.

[jayvee43]

I really enjoy this thread Barrie, Very informative.

I got your pm, I answered you

Jesse

[Barrie2777]

Sometimes there is an odd bolt left over after a rebuild. I guess I'll toss this one in the garbage!

[snocatpete]

Hey Barrie I agree with jayvee43. You certainly are sharing lots of info on this restoration.
Glad you mentioned the choke cable holder as this part is an important part to proper choke operation. I have seen a lot of machines without this part. I use one very similar to the one you use only it is a two piece clamping type and using the same hole on the engine that you use. With the cable adjusted properly, makes the choke operation a whole lot easier. I also see you modifying your choke cable. I found a perfect replacement for the choke cable. It is virtually identical to the original. I got it from Napa and the # is 7-03971. Of course this is a lot longer than original but you just have to trim it to size.
I also noticed in one of your pictures you are missing the stop switch button. I assume you have it but if you don't, you can buy a new one. Standard make a replacement and their # is SSB-3 and you can also check Cole Hersee #9059. Of the two, I prefer Cole Hersee BUT I think 9059 has been discontinued??? although I think you can still find the Cole Hersee on ebay.
Could that extra bolt that you want to toss away possibly be the plug from the bottom of the crank case on the engine as it looks like it has a gasket on it. Just a thought...
You have this 400 looking awesome. I think you have a good chance to win those Hus ski skis for best restoration this January in Port Washington...lol !

I have included some pics.