Reluctant Project - Cooley Barn Find

[chuck hahn]

Gregory brought the bike up to me to see if it was worthy of screwing with. Here is what i know for certain...

All the lights and gauges work ( clock, oil temp, all dash lights, etc etc ) in spite of the dash glass being shattered. Will have to repaint them all once I get into rehabbing the cluster.

The left side engine mount cavity where the tear drop goes up in has been snapped but we have the piece and,it can easily be rewelded on..no big deal.

The stator cover is split open but there is no damage to the rotor....far as i can tell. Will know more when i actually take it off.

Now here is the real kicker!! I wrapped then stator cover with duct tape to patch the hole so I could at least get oil in to see if it was a runner. So after some fiddling to get the ignition out so I could use a screw driver as a key ( we dont have keys for it yet ) and using a car battery for power....she has fired up and not one suspicious sound from the engine and absolutely NO SMOKING!!!! So, heres some not so flattering pics and a link to a video of it running. Click on the bottom pic ( linked ) and it will rediredt to the video.

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[Gregory]

You are the miracle man chuck, way to go!!!

 

[chuck hahn]

OH...This ones gonna require MANY MANY more miracles before its over!!!! Now that its verified a solid engine, the next step is disassembly down to the frame and start the reconditioning process.

Gotta go get sand paper, laquer thinner, paint and other supplies. Greg, download the pics into an album somewhere for your records.

 

[Guest]

Very creative Chuck/Greg. I never would have thought of the duct tape stator cover. This looks like a pretty big project, but I'm sure you can do it, good luck. Ray

 

[Frank Z.]

Nice start guys. Good to see another S model revived, and glad those junk carbs have a new home.

 

[Stahlgrau333]

Chuck, between the Cooley, my 550, and some of the other crap we've got laying around the shop, we should name it "Resurrection".

 

[chuck hahn]

As of 7:12 PM Oklahgoma time she is fully disassembled. Now its start sanding and getting the chassis redone. Then get the rims polished and repainted. Will make a roller and add things back on as they are rehabbed.

 

[chuck hahn]

Everything is cleaned and painted ( except the frame ). Being cycled thru my little oven to bake the enamel. Still have to rebuild the cash and clean and paint the gauge needles, but the bulk has been tackled. Just over 40 total hrs so far into rehabitation.

 

[Vmass]

Thanks Greg............and good luck with the project.


Subscribed!

 

[chuck hahn]

As it sits right now, I have everything repainted except the frame. I also need to rehab the dash..it needs a new glass, which i plan on replacing that with Plexiglass or Lexan.

All the lights, the clock, and all the gauges work. I will clean the gauges faces when i get them apart, repaint the needles, and it will be like nothing ever happened.

As I start the reassembly process I will start posting pictures to this thread.

 

[chuck hahn]

Frame is painted. Using the propane torpedo to pump heat around it so the paint can gas off, not freeze and start to cure..for now. Its gonna need to set a week probably to harden real good. Everything else is done ( paint wise ) and the reassembly will soon begin.

 

[SVSooke]

Did you use Appliance epoxy on that frame Chuck?

 

[chuck hahn]

My standard go to...VHT Gloss Black Epoxy masked off the VIN sticker so it wasnt lost too..did ya notice???

 

[SVSooke]

Yes Chuck I noticed the VIN tag.

 

[Gregory]

And I noticed you painted your deluxe lift table white too

 

[chuck hahn]

Yeah...LOL. I mentioned when i built it that the previous tenants had left half a 5 gallon bucket of paint...so its what it got!!!!

 

[Crankthat]

Nice score Gregory!!
Always figured you for a good guy Chuck!
I have subscribed and looking forward to watching it come back to life.

 

[chuck hahn]

Greg calls me " A good egg"....LOL

 

[chuck hahn]

Cleaned the chain guaurd ( didnt take a pic of it ) and the two plastic inner fender pieces today. here the frame out in daylight also.

 

[chuck hahn]

Broke down the forks and shined the lowers up. Had to swap a tube out because the original one was too pitted. Luckily I had several 1000 forks around for a spare. Theres a shot of the one as compared to one thats untouched..dramatic difference.