Operation: Battle Panda or: Getting the Airhead Ready for 2up Adventure

Discussion in 'New Zealand' started by igormortis, Jan 16, 2012.

  1. Padmei

    Padmei enamoured

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    WHo's ging ove rto Russia with you? How long do you expect to be away? Why Russia?
  2. igormortis

    igormortis Long timer

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    Geez, you sound like a border guard! My wife, Penny. Dunno. And coz it's there!

    In truth, I don't really know how to answer completely when asked why. It sort of evolved to this point.

    Neither Penny nor I have really done an OE as such, and I always liked the idea of not just taking a plane to Europe, but rather pointing a motorcycle in the general direction and actually travelling somewhere.

    I always get a weird displacement kind of feeling when I fly somewhere, even Hamilton. A kind of mini jet-lag maybe. I don't like getting into a container and turning up somewhere else. I want to see the scenery change, feel the seasons catch up to us, and see faces join dots from culture to culture. That's probably the heart of it.

    Dreaming about it has given us both the wanderlust. The stepping stones across the ocean lead to Russia, so at some point that became the natural starting point, and now it's stuck.

    I'm still busy scraping, sanding, and painting, but soon we'll give our humble abode up to tenants. I've all but left my job and become a renovator/mechanic at home, and Penny has given her notice.

    I have an idea that we'll arrive dusty, dirty, and dishevelled in the Dutch lowlands, where we have offers of couches, floors, and bedsits. I have a passport that let's me stay, and Penny has a pair of Derby skates that automatically lets us in to a social circle. From there, I have no idea. If we, marriage, the bike, and the bank balance survive, then we'll stick it out for a while. Otherwise, there's always a little house in Wilton to come back to...
  3. innathyzit

    innathyzit AKA Woodman

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    Goodonyas.....................
  4. Voltaire

    Voltaire Bored Of The Rings

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    Sounds like fun, The first day I find when flying in is a shock but after a while you just go with it.... I went to Moscow and the then Leningrad in the later 80's, saw old Lenin....hope the food has improved.....:rofl
  5. Zebedee

    Zebedee Been here awhile

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    Sounds familiar ... a couple of mates did something similar a couple of years back, RR here ... I'm deeply, deeply envious.

    :beer

    John
  6. Kokopelli

    Kokopelli Yeah, right!

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    Will you start a separate report, or just continue on here? Had to post something to subscribe. I'd love to do something like this, but I guess we're already too entrenched. Plus the "kids" show no sign of movement.
  7. igormortis

    igormortis Long timer

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    Had a good chat with Michael over Skype a while back - super helpful!

    I think I'll stay here 'til we leave, then open it up to an "international audience" once we're out in the world.
  8. Zebedee

    Zebedee Been here awhile

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    I don't know Michael as well as know Wayne, but yeah, good guys the pair of them ... :thumb

    Good luck with the final prep, I look forward to the thread going "international", I'll be cheering you on from the cheap seats ... :D

    :beer

    John
  9. advNZer?

    advNZer? Long timer

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    how about a pic of the bike...
  10. Zebedee

    Zebedee Been here awhile

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    Gimme' a clue, which bike? ... :evil

    A good few years ago now but L to R, Wayne's (before he went "Orange"), mine and mine (the oilhead's off the road for the foreseeable future).

    [​IMG]

    ... but I'm sure we're all far more interested in progress with igor's bike ... :D

    :beer

    John
  11. advNZer?

    advNZer? Long timer

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    yes,,not quite sure how i quoted you...nice pic though!:clap
  12. igormortis

    igormortis Long timer

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    So here's the bike we're taking across the world in a couple of months - yikes. Can't think of how many pieces it's in - just gotta tick off the jobs one by one.

    <a href="http://www.flickr.com/photos/58374333@N07/8543359321/" title="P1050812 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm9.staticflickr.com/8102/8543359321_9d78d05c31_b.jpg" width="1024" height="768" alt="P1050812"></a>

    Dropped the oil and sump today...

    <a href="http://www.flickr.com/photos/58374333@N07/8544695926/" title="IMG_0041 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm9.staticflickr.com/8228/8544695926_fd71058e24_c.jpg" width="600" height="800" alt="IMG_0041"></a>

    ... with the intention to fit this:

    <a href="http://www.flickr.com/photos/58374333@N07/8543600531/" title="IMG_0058 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm9.staticflickr.com/8529/8543600531_e096c143d0_b.jpg" width="1024" height="768" alt="IMG_0058"></a>

    Looks like the HPN rallye sump, but a different casting - being uniform in depth, rather than narrowing to the rear. Cleaned up all the surfaces and deciphered the German directions before wondering - does the Drei-Bond go on all mating surfaces?

    Had a quick check online to see what the internet says. Shockingly, the internet says that the sky is falling. [yellow font][supershaft][etc]NO ADHESIVE - EVER[/yellow font][/supershaft][/etc]

    So, taking all that for what it's worth and thinking about it - perhaps the Drei-Bond should be used only between the bottom plate and the spacer ring, sandwiching the gasket semi-permanently. Then the assembly should be installed like a normal sump presumably, with a dry gasket.

    Thoughts?
  13. igormortis

    igormortis Long timer

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    The other concern is the oil pickup. It's a BMW part and a completely different casting, positioned lower than the piece it replaces to take advantage of sumps with greater oil capacity.

    <a href="http://www.flickr.com/photos/58374333@N07/8544696290/" title="IMG_0054 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm9.staticflickr.com/8088/8544696290_f405c019e2_b.jpg" width="1024" height="768" alt="IMG_0054"></a>

    But it needs to be machined to work with the aftermarket casting, and someone didn't do the greatest job:

    <a href="http://www.flickr.com/photos/58374333@N07/8543600205/" title="IMG_0056 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm9.staticflickr.com/8236/8543600205_e1cb866dcd_b.jpg" width="1024" height="768" alt="IMG_0056"></a>

    I'm not confident that this will seal properly, and I won't happily leave it like this for something as critical as an oil pick-up.

    I'm concerned with how much of the bike is currently distributed across the Greater Wellington community of engineers and specialists. So who thinks I can satisfactorily flat this out with hand tools and abrasives from my tool box?
  14. Zebedee

    Zebedee Been here awhile

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    If Mike (aka StigNZ) can rebuild a clutch in the middle of a mossie infested Mongolian swamp, I've got every confidence that you can sort out an oil pick up in the greater Wellington area ... :thumb

    May the force be with you.

    :beer

    John
  15. Box'a'bits

    Box'a'bits In need of repair

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    Re the sump gasket, it's a heat activated seal. Once on they are hard to get off. However when I put mine on I put a really fine smear of goo to allow the gasket to be removed in one piece should I want to get back in there.

    Re the 'pick up', fine sandpaper & flat surface should do the job (maybe a piece of glass or steel). Be careful not to round it.
  16. clintnz

    clintnz Trans-Global Chook Chaser

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    Put some sandpaper on a flat thing (like a bit of glass) Rub the widget on it trying not to rock it around too much.

    Cheers
    Clint
  17. igormortis

    igormortis Long timer

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    Thanks guys... Spent some time with varying grits of sandpaper and a piece of flat steel. And I thought I was done with the sanding. :huh

    <a href="http://www.flickr.com/photos/58374333@N07/8546394930/" title="IMG_0061 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm9.staticflickr.com/8244/8546394930_824229889d_c.jpg" width="800" height="600" alt="IMG_0061"></a>

    <a href="http://www.flickr.com/photos/58374333@N07/8546395412/" title="IMG_0063 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm9.staticflickr.com/8093/8546395412_07eaa9edd2_c.jpg" width="800" height="600" alt="IMG_0063"></a>

    There's some very slight rounding now, but it checks out pretty flat on a pane of glass. I'm thinking that with a gasket and a slight smear of the Drei-Bond, it'll be OK.
  18. igormortis

    igormortis Long timer

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    About to tackle the clutch. I don't need to take the flywheel off, do I?
  19. Box'a'bits

    Box'a'bits In need of repair

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    Nope. But you do need to figure out how to hold it while you take out the bolts to the clutch carrier. I just jam it up, but there are prettier ways to do it. :D.

    Technically you should mark the plates so they go back together as a balanced assembly, but given the age of your bike the clutch will have been replaced, and I bet they didn't do that then.

    I have a tool that makes reassembly easier (sits in the clutch splines to centre everything). You are welcome to borrow if you want.
  20. igormortis

    igormortis Long timer

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    That was easy... everything I do makes the bike look less like a bike. Let's not dwell on that tooo much...

    <a href="http://www.flickr.com/photos/58374333@N07/8548163888/" title="IMG_0096 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm9.staticflickr.com/8390/8548163888_b2e84ca123_b.jpg" width="1024" height="768" alt="IMG_0096"></a>

    Not a flywheel at all, is it? Just a clutch and ring gear carrier.

    The bolts were worryingly easy to undo, didn't have to jam anything up at all. Just turned the engine till the angle was just right and the bolts cracked loose. Note for future assembly - loctite?

    Steve, I saw the balance holes and made a note of the orientation - but no way of knowing if they were aligned correctly - though there were some paint marks which may indicate yes. The clutch is marked 9 '88 - the same month and year of Battle Panda's production, so good bet that it's the original clutch.

    <a href="http://www.flickr.com/photos/58374333@N07/8548164216/" title="IMG_0097 by c00300875c487ce28b95948225d005e0, on Flickr"><img src="http://farm9.staticflickr.com/8514/8548164216_7c17257925_b.jpg" width="1024" height="768" alt="IMG_0097"></a>

    Not sure if I should replace the two plates (bottom) as well as the clutch disc and diaphragm spring. Currently thinking that it's better to press on with the parts I have at hand. Any merit in getting the plates resurfaced locally?