MBBO Won’t finish: Savage B.O.B.

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Saw my color out in the wild today.

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As I figure out how to get this back end to work, the devil is in the details. This original locking washer for the sissy mount has a tab that sticks out a little far, so I ground it off them. That way the new sissy mount can butt right up against the frame.
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I checked out the caliper and the space it will need. I’ll need to design some mounts. The goal will be to get them to look like seamless parts of the frame.
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Before I do any of that I need to get the rear wheel and fender situated. I need to move the lower fender mount back, so I cut it off and cut back the extension. (No pic). I’ll also need to move the brake brace up, so I’m just replacing it since I don’t need the brake mount hole. So I cut.
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And smoothed it out
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On Friday I’ll work open the frame a little more with some dimpling, and weld in the new pieces.
 
The new lights came in. They are bigger than expected as well! It said 4.5” x 4.5”, but that’s the lens. It’s more like 4.75” across and 5” tall at the shell.
My original plan was to double them up, stacked at an offset. But if I stick with this design, maybe I’ll only use one. I might need to set up the fender first.

Hmmmmmmm

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In order to set up the fender, I need the front wheel. It’s ready, but my OCD got hold of it. There weren’t a lot of choices for a 16” rim with 36 holes, I got this aluminum rim. It has a raised ridge, and a cut valley, I guess just for texture.
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I just want it smooth since it will be painted. Smooth shows the finish better. So… I broke out the orbital sander.
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I’ll take are of the valley with some body filler.

I bought this cheap “low rider” 16” fender for the front. I’ve used one before, but this time I couldn’t find one without these holes.
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I forgot to get a pic, but we filled them with weld. I dropped the front and rear fenders off to have the chrome stripped off. It’ll make cutting and shaping it easier.
 
I’m converting this bike to a 5-speed with a rear disc brake. So the rear triangle needs more room. And do you see how ridiculously big that lock nut is? I don’t need that kind of space, so I switched it out to a thinner one. The wheel will be disassembled and reassembled later, and I’ll address the change in dish when I do that.
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So I broke out my handy dandy spreading tool.
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Once it was cranked open to fit, I had to fix the change in angle for the dropouts.
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Better
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I’ll have to check alignment again after I dimple the chain stays to get a fatter tire in there. Plus I’ll have to check frame alignment. That’s coming up.

But for now the hub fits.
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Awesome.
 
Sometimes I just have to stop before I start throwing things. The front tire should be easy. But it was a bear to get on. Then when I did, I can’t get the stem to pop out far enough to get the pump on it. It’s a deep rim, so I figured I can find an extended stem tube… but I’ve looked. Nothing. So I’ve hit a wall I can’t see around. Time for a break.

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Did you have any air in the tube? If not you can pull it out and put just a bit of air in the tube that should push the stem through. Can't imagine that rim was made to use an extension.
 
Sometimes I just have to stop before I start throwing things. The front tire should be easy. But it was a bear to get on. Then when I did, I can’t get the stem to pop out far enough to get the pump on it. It’s a deep rim, so I figured I can find an extended stem tube… but I’ve looked. Nothing. So I’ve hit a wall I can’t see around. Time for a break.

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Look for a specialized tube the have the longer stem but not sure they make tires that small
 

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