Research Opportunity

This project never ceases to amaze me. This motorcycle at first glance seems so simple; a bicycle with no transmission, no clutch, no lighting, and only a coaster brake. Yet such a “simple” machine is oh so complicated! So when a good friend offers to take me to see a complete 1911 Excelsior for reference, you HAVE to go! A wonderful day looking at this original running machine!

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Fork Springs

All six fork springs were able to be removed unscathed. However I will not be using them in this project. Seems there are a good amount of suppliers of this type spring so we need to determine spring “force” to make sure the correct springs are obtained. Here are some details of the springs and how we tested them. 


Slow and steady progress

Here’s a shot of the fork during the repair process. As you can see the welding is complete on the one top fork shaft. New inner springs are on the way. Also in process are the lower rockers getting new brass bushings for the fork pivot studs and front axle. Hope to have this back from the machine shop by the end of the month.

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Machining continues

Slow steady progress. Here is the new bottom fork rocker studs; original compared with the new piece. 

And here is the old handlebar throttle sleeve and the beginning of the new one. 

I am thrilled at this continued forward momentum. Still a long way to go! But as I always say, slow and steady progress! 

Machining In Process

As my earlier post revealed, there is some machining required on my front end. A good friend owns Milwaukee Mold Industries and has agreed to tackle this for me. There are a number of machining events that will be taking place over the next few weeks: handlebar work, repairing the broken off top fork tube, machining new lower rocker studs, and machining the lower fork rockers to once again be in tolerance for studs and axle. I’m thrilled this is moving along. Thanks MMI! 

Here is the left bar after MMI was able to remove all of the rusted grip sleeve off. 

Here is the right sleeve removed that was frozen on. 

Initial steps to locate the repair on the fork tube. 

Rear Wheel Rolling Along

Every little event that keeps this project moving along is monumental, in my mind. I was like a little kid when the rear tire and inner tubes showed up! I carefully unraveled the wrap on the tire. I inflated the inner tube over the rim (just for fun). And then just sat back and gazed. So close yet so far. 

Removing the riveted on belt brackets from the old rim will be a huge task, as will attaching to the new rim. 

But for now, I am happy all rear wheel parts are here.