The 442

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Spent a good amount of time with 2000 grit sandpaper. The guy who did previous consoles for me emphasized prep, saying the spray accentuates every imperfection, and sanding down to 2000 grit. The most I ever did was 800, and it looked fantastically smooth when I sent it, and then I could see all the flaws when it came back. So this time I spent the time with high grit to make it as flawless as I could. We’ll see. It’ll be off to Canada tomorrow.

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As you saw, the disc brake caliper wouldn’t clear, so I had to figure out a way to dimple the stays without affecting the outside of the tubes. @RustySprockets offered a genius solution. Get a harbor freight pair of bolt cutters and modify them. So, for $20 I got a set. At work, I cut a piece of 3/4” rolled stock and piece of HREW pipe, then cut the pipe in half.

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I took them home and ground them smooth because I didn’t want sharp edges affecting the bike frame’s metal.

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I cut some chunks out of the bolt cutters (and the cutting edges) and welded the two pieces on either end. Took them home and smoothed them out again. This is it opened up.

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And closed. I made it so it wouldn’t clamp completely because I worried about hurting the frame.

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So I went back to work and had one of my guys fire up the torch (literally), heat the metal up, and I crimped it. The metal was almost gooey, and crimped super easy.

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I got it home for closer inspection. Here’s the crimped side and the drive side for comparison.

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What I won’t know for a week or so is if it actually worked. The wheel is awaiting spokes. My spoke guy said done this weekend and shipped on Monday. So I’ll get that rear wheel laced up, mounted with the brake, then I’ll test the fit and make adjustments. Meanwhile I can work on smoothing out the frame’s metal. There is a good bit of rust pitting I need to smooth out.
 
To give the top end a cleaner look, I tacked a fender bolt into the mounting hole and will secure the fender from underneath. The bigger question is: so I try to fill in the brake mount hole? I did it on the Super Fueler and it was honestly a big pain in the rear to make look right. And this will be even more difficult because of the small space right next to the fender tab. But maybe I could just take a bolt in there and fill it in with JB weld which would be easier to shape? Or I could just leave it, which is the easiest answer of all. I don’t know.

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CRASH said:
So I’m going to have to figure a way if crimping the inside without screwing up the outside. @Pondo how did that crimping tool work? I may have to make one.
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CRASH said:
So I went back to work and had one of my guys fire up the torch (literally), heat the metal up, and I crimped it. The metal was almost gooey, and crimped super easy.
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This very cool project is looking great CRASH! Sorry to take so long getting back to you on this. With other things I need to work on plus non-stop weather I haven't been working on my bike projects and haven't been checking in to the forums.

It looks like you got it handled pretty well with the dimpling tool you made. I was having an issue with my frame wanting to crush the outside a bit and not do too much on the inside. My next step is going to be to heat up the inside of the frame pretty good, looks like it worked great for you. I stopped working on my Cheater Slick when I realized I wouldn't be able to get it painted by the build off deadline, but I will get back on it at some point.

As usual you're doing fantastic work on this build, NICE!
 
I’ve had a lot going on, so here’s an update from the last 3 weeks or so.

Despite the first crimp, the caliper still didn’t have enough clearance.
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I had to go through about 3 more rounds of hearing and crimping to get it right. But I eventually got it.
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So to get this kind of caliper to actually work it needs a little tab to stick out of the frame. So I stylized one. Here’s the mock up of the cardboard cutout.
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So I traced it on a piece of scrap.
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And cut
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And here it is in comparison to the cardboard which is on top.
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I shaped it and smoothed it. Here’s how it’ll sit.
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Then had it welded in place.
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That’s where I’m at so far.
 
Nice work so far. This is gonna be good. Love the bolt cutter mod. I just picked up another muscle bike project and this is motivating me to actually work on it. Mine is a drum brake though. Original right down to the tires. Has never even had a wheel removed.
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markthatcher1 said:
It is Sailor. Got to watching Crash and the other builders take The bikes to another level of thinking. I have quite a few stock bikes, and kinda got interested watching these guys. We have stock 442s and modified, so we figured what the hay. May be cool. And I agree, Maistro!
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I love car themed bikes especially muscle bikes based on muscle cars. Check out my build "The Bandit" based on the Trans Am Burt Reynolds drove in Smokey and the Bandit.
https://ratrodbikes.com/threads/bandit-klunker.118049/
 
The severe weather in California recently is going to hit the nut (almonds & pistachios mainly) harvest hard. Because of that, big orchards have been canceling contracts with my place of employment, so they made the hard decision to shut down production until they figure out what this year will look like. So I, along with about 120 other guys, was laid off. So now I’m looking for work, and poking around this project when I have time.

I had a lot of small part polishing to do for all the Lark derailleurs I’m restoring. Looks like I can make 5 out of this round. The best one is going on this bike, and was completed first. So today I mocked up the drive train to ensure everything is aligned, which it is.

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Next I’m going to figure out the brake cable routing. I toyed with the idea of going internal, but if I screw something up, now I don’t have welders readily available to weld for me.

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CRASH said:
The severe weather in California recently is going to hit the nut (almonds & pistachios mainly) harvest hard. Because of that, big orchards have been canceling contracts with my place of employment, so they made the hard decision to shut down production until they figure out what this year will look like. So I, along with about 120 other guys, was laid off. So now I’m looking for work, and poking around this project when I have time.
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That sucks man. Hopefully they get it sorted or you find something in short order
 

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