Easter

Many things were accomplished, not including stuffing my face with chocolate here's what happened.

Finally moved the bike outside and assembled things

Added the fender

Assembled the pivot back on to the final drive

With the cardan shaft and rubber bits..

Then my shipment of nice new tires arrived.

 It seemed appropriate (given the weather) to have a look at the condition of the side car,. as it is the largest element,and i haven't touched it yet.

It was revealing..

quite a bit

of outside

But, repairable.

Holey

crap

and a nice close up.

the other sill wasn't to bad.

just thought id put it there to keep out the way for now.

It became quite windy the next day. so my efforts were concentrated on inside activites...

Gearbox lid off

Crap gasket

Gears out. Covered in some goo

Needs a clean..

Some other gearbox components, all cleaned and shiny

Some more clean bits, the main gear stem, kick starter gear and the drive shaft.

Dirty Case

Clean Case

Dirty Insides (yes i accidentally dropped the bearings out of the clutch mechanism..)

Cleaned inside case

Shiny

Kick-starter Gear Back in

Cleaned - reassembled gears.

 I have not yet put the gears back in, as i'm waiting on a shipment from Ural-Zentrale and a few other sellers, one of which contains a new set of seals for the gearbox. I popped this to the side and continued..

I think the cylinder heads need to come off.

As is..

Head off. Looks quite clean

Like new piston.

No wear on the sides

Just a bit of soot on the top, and oil on the side. Thats it. I may believe this could actually have only done 7500 km. (perhaps since last engine overhall?)

Tappets looked worn, but usable, something ill replace later.., surrounded by treacly oil residue.that needs to come off.

Cylinder head. The inside tube was spotless. no wear marks. nothing. Valves left a lot to be desired, again replacement needed, but later..

Cylinder Heads Off

and again

Generator - i think i remember the previous owner staing something about the generator, that it may not be working

Hmm, i don't recall any electrical generator requiring oil to run?

Thats a lot of oil for an area that shouldn't have any, There was no seal between the generator and the timing gears.- maybe that's why it didn't work.

Those bastard clutch screws

(after extended time removing those clutch screws) Down to the flywheel.

 Ive decided something. Those clutch screws are bastards. Some of/the previous owner(s), had bodged them all in, ruined the heads in the process, making extraction challenging.
Awesome.

Getting them out was a bit of a job. I dont think its ever taken me 2 hours to remove 6 screws before.

They came out in the end (after chiseling in new slotted heads and the application of a long breaker bar with screw attachment and a bit of pressure..).


Needless to say i ordered new ones.

Next day, the wind had gone, and was sunny again. So i called my dad up, and he appeared with a welder and we set to work repairing the sidecar..

After a clean up but before welding..

Strengthening bracket tacked in place

New side tacked in place.

Starting to fill in the holes. It not pretty, but certainly very strong!

More hole filling...

and some more hole filling..

Making sure its stuck on..

 Base sidecar clamp plate reconstruction

and some more clean up

there's a bit in between i forgot to photograph, but you get the idea..
the next day was spend making small metal patches and filling out the smaller holes, and then the afternoon spend, doing a bit of grinding sanding and painting...

Starting at the front, (ran out of grey, local shop only had red, Red it is then)

Sanding the side and back

Painted

Painted

What welds?

With a bit of filler over the welds it would look quite good! :) i think the repair is actually stronger than the original metal!

I need to look at the inside of course, but most of this is just surface rust, and will come off easy.