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Pa's 42WLA Build

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knucklebolt

Posts: 221

Joined: Tue Feb 12, 2013 8:27 pm

Location: Six miles East of Cheney, Wa.

Post Fri Jun 13, 2014 11:13 am

Re: Pa's 42WLA Build

That's true, old-tech was at least straight forward and logical. Much like, old bikes and new bikes. Working on my son's mid 2000 Sporter right now, it's not sparking. Old school, just check the points, condenser, coil, and is the circuit breaker turning. This sporter, like three or four pages in the manual devoted to testing in order to figure it out. !!!

Anyhow, you are doing a fine job in spite of the bumps in the road. I sure love those engine pics.

k.
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Pa

Site Admin

Posts: 4715

Joined: Sun Mar 12, 2000 1:01 am

Location: Ohio USA

Post Fri Jun 13, 2014 2:05 pm

Re: Pa's 42WLA Build

I think I set my sights on repairing my rear oem mudguard [fender] assembly at about this time. For the life of me I don’t know what possessed me to buy it. Maybe I bought it because good usable oem wla rear and front mudguards are really rare and difficult to find. If you do find good ones the price is for the deep pockets person. As you can see from the pics below, it was a real mess.

Note the barn door hinge and how offset it was mounted on the mudguard. Look at the crapshoot rivets used. My nos wla rear mudguard section with correct hinge is to the right.

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Look at the luggage rack tab mounting holes. They were miss located and a reinforcement plate had been nonprofessionally have ass riveted to the underside of the mudguard.

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The chain guard mounting boss was cut off of the brace.

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Chain guard clearance in mudguard was all tore up.

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Lower front frame mounting area was misshaped with a half ass repair to it using a backside reinforcement plate and numerous rivets.

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These reinforcement plates do not belong there either

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Another view of the crappy front repairs.

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One more view of the mudguard. You can see a bobbed wla mudguard behind the mudguard.

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My fix for all of the damages was to first remove the braces and then measure out the radius of the mudguard so I could build a fixture to mount the mudguard on while making the repairs. I built the fixture out of wood. It had two 1” thick sides to support both sides of the mudguard and it had the area of the full sweep of the mudguard radius, which included the hinged rear mudguard section, front to rear. I next staked a pair of stops on one end of the fixture for the mudguard to rest against. I began to lay out the sides of the fixture where all hole locations should be in a wla rear mudguard and marked them clearly. I used a flexible hacksaw blade as a straight edge and scribed horizontal lines across the mud guard in the necessary hole locations. The necessary hole locations consisted of fender brace rivet holes [ which were not disturbed ]. I knew those fender brace holes were original and I could work my way forward and back in order to lay out the other hole locations for the luggage rack front mounting tab screws and the rear hinged mudguard rivets. With this all established, I cut off the front section of the mudguard containing the upper and lower battery box mounting brackets. I then cut the wla bobber mudguard, which had both oem upper and lower battery box mounting brackets in the correct locations, to replace what I cut off of the beat up mudguard and welded them together using my fixture. That was a real pain in the ass to do. Next I removed the rear hinged section, welded in chunks of sheet metal which I also cut from the bobber mudguard, and replaced the parent metals of the mudguard skin and underside reinforcement. I then cut out the correct location for the hinge. I filled in all the additional holes that had been put in to the mudguard over the years and I installed a pair of nos braces/rivets and an nos chain guard bracket/rivets. With all oem rivet and screw hole locations in place now, I mocked the mudguard up to my frame. She fit like a glove !! I finished the skin cosmetics, painted it, and set it aside for later installation. Mudguard dimensions used in relocating hole locations, including hinge rivet holes, hinge clearance opening, and hinged mudguard resting area of forward mudguard section, were taken from a drawing I did in a paint program years ago but have since , like many of my files, have lost it. That drawing is however floating around on the web somewhere. No pics of the un-mounted finished rear mudguard either but you will see it in several views on the bike later on.
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Pa

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Location: Ohio USA

Post Sat Jun 14, 2014 6:30 am

Re: Pa's 42WLA Build

During this period of time, I picked up this nos ammo box. It is the high mount type with full length hinge which is correct for my early type III 42wla. Upper springer mounting strap was a little tweaked but not a big deal. Adjust that and paint and presto….ready to mount. I got to the tweaking after I was far along with the build to mock fit it up to the bike. As with much of my files, you will see it on the bike later. Sorry for the crappy pics. I used a flash with some and no flash with others.

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Pa

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Posts: 4715

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Location: Ohio USA

Post Sun Jun 15, 2014 7:14 am

Re: Pa's 42WLA Build

And here was my nos rifle scabbard bracket before refinishing. Factory tag was missing when I bought it. One might ask…why did I believe the seller that the bracket was nos ? That question was answered two fold very easily. Number one, the seller is a good Australian friend of mine and his character is flawless. Number two, there are no impressions whatsoever in the mounting straps where the bracket would have been mounted to the springer. On another note, Take note of the details in rivets and welds. I will post pics of an aftermarket one to show differences.

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Photobucket editor quit working. I'll post 4 more pics of my nos rifle scabbard later.
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Pa

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Location: Ohio USA

Post Sun Jun 15, 2014 3:00 pm

Re: Pa's 42WLA Build

4 more nos scabbard bracket pics

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Pa

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Location: Ohio USA

Post Sun Jun 15, 2014 3:02 pm

Re: Pa's 42WLA Build

I only have a few reproduction scabbard pics but you will defimately see the differences between oem and reproduction.

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john HD

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Location: madison wisconsin usa

Post Sun Jun 15, 2014 6:51 pm

Re: Pa's 42WLA Build

PA,

really enjoying your thread. brings back memories of when i did mine.

Question, are you going to install the aux. field relay for the black out lights?

john
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Pa

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Posts: 4715

Joined: Sun Mar 12, 2000 1:01 am

Location: Ohio USA

Post Sun Jun 15, 2014 8:13 pm

Re: Pa's 42WLA Build

john HD wrote:PA,

really enjoying your thread. brings back memories of when i did mine.

Question, are you going to install the aux. field relay for the black out lights?

john


Absolutely John. Coming up as the thread resumes.
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George Greer

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Location: Markt Einersheim, Germany

Post Sun Jun 15, 2014 10:22 pm

Re: Pa's 42WLA Build

Paul...

Good thread! Really enjoy the photos, and you taking the time to document this bike.

I've been looking after finding a NOS rifle holder, and tool box but everytime I see one here in Europe......well....it just don't work out. But good thing you got yours!.

Are you going to be using the leg guards as well?

George
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Pa

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Location: Ohio USA

Post Mon Jun 16, 2014 6:09 am

Re: Pa's 42WLA Build

George Greer wrote:Paul...

Good thread! Really enjoy the photos, and you taking the time to document this bike.

I've been looking after finding a NOS rifle holder, and tool box but everytime I see one here in Europe......well....it just don't work out. But good thing you got yours!.

Are you going to be using the leg guards as well?

George


I looked for years before I obtained a real deal scabbard bracket. The rare few I tried to score in the past were grabbed up by deeper pockets than mine. My Australian friend remembered I had been searching for one and he got in touch with me with the good news he had found me one. He purchased a large lot of parts and low and behold, the scabbard bracket was in that lot. I never did find an nos tool box but I did score a decent oem one which needed a bit of TLC.

I don't remember why I documented details as I did George. Force of habit I guess. I have the leg guards and will mount them for pics but I probably won't ride the bike in winter so I'll pull them right back off. Mounting them will help line up all the mounting hardware and brackets and permit me to lock the mounting brackets in place for later installation of the leg guards.
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Pa

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Posts: 4715

Joined: Sun Mar 12, 2000 1:01 am

Location: Ohio USA

Post Mon Jun 16, 2014 8:24 am

Re: Pa's 42WLA Build

I found another lost file !! This one is on the engine bottom end. NOS flywheels, pinion shaft, sprocket shaft and rod assembly. All lapped in, fitted, and ready to assemble flywheels.

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Pa

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Location: Ohio USA

Post Mon Jun 16, 2014 8:32 am

Re: Pa's 42WLA Build

My springer.... I cannot take the credit for my springer. Steve Lemay put it together for me. Steve did an excellent job. I needed a brazed springer and Steve was the man to ask. Only one issue makes my springer incorrect for an early type III 42 WLA. The date code on the spring fork is a bit later than what my bike would have left the factory with. Then again I thought.....Since the theme of my bike is how it returned from war duty, Who is to say the spring fork was not replaced during the war ? After all, those men beat these bikes in active duty. Though my spring fork sports a bit later casting code, it still is brazed.

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Pa

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Location: Ohio USA

Post Mon Jun 16, 2014 9:00 am

Re: Pa's 42WLA Build

Back to the subject of mudguards, Though I lost my front mudguard pics, I did find the pic below in my files. I created the pic from another oem front mudguard because my oem front mudguard was missing the upper inner support bracket you see in the pic. I took dimensions and applied them to the pic so I could duplicate the support bracket and put it back in to my mudguard. I did this and it turned out great. My front mudguard skin needed several holes filled and the front tip hammered back into shape. I also installed all nos braces and rivets. Did I mention you will see the front mudguard in this topic later on ? LOL

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Pa

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Location: Ohio USA

Post Mon Jun 16, 2014 1:04 pm

Re: Pa's 42WLA Build

Oley AMCA swapmeet was coming up and Michael Paquette of Worsham Castle Cycle Leather informed me he would be at the swapmeet. I figured I would take along my oem worn out wla seat and turn it over to Michael for restoration. As you can see in the pics below, my seat needed help.

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The below pics show the results of Michaels work. I asked Michael about the over spray of drab olive paint on the seat pans bottom but Michael assured me he has plenty of documentation showing that is how the factory did the wla seats and I am very happy with that.

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Pa

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Location: Ohio USA

Post Tue Jun 17, 2014 6:49 am

Re: Pa's 42WLA Build

Sorry to jump all around in this topic but I came across the following data pics while searching for other lost files. I took the data from other oem front mudguards. That data helped me restore my front wla mudguard. Maybe some of you can use the data. Most of the data applies to civilian mudguards as well.

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I had also acquired these little gems in my parts collecting. How often do you see wla nos mirror and mounting parts ? Pic is of how the parts looked when I obtained them. You will see the restored mirror as mounted on the bike later.

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If I can recall correctly, I scored this nos Cycle-Ray headlamp reflector from Fran-6, a long standing member of this forum. I also scored nos headlamp socket wiring to replace the cut off ones in the nos refector. This reflector allowed me to complete my restoration of my Cycle-Ray headlight assembly. Only the bucket of my Cycle-Ray headlamp assembly is oem. My oem bucket was tweaked out of shape but I got her back into shape with lots of patience. All the other components of the headlight are nos, including the correct glass lens with a #1 mold mark. You will see the light mounted on the bike.

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I picked this oem machinegun scabbard up along the way as well. Note U.S. Boyt 42 stamped into it. Boyt was one of several rifle scabbard manufactures for the wla. It was missing the brass tie down strap loop. I made an exact copy brass loop to replace the missing loop. Sorry no pic of my loop until you see it on the bike.

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Pa

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Location: Ohio USA

Post Tue Jun 17, 2014 1:02 pm

Re: Pa's 42WLA Build

It was time I spent a little time on considering wire routing. Some wiring needs to be in place before certain parts can be added to a wla. The timer wire I used was already in the timer and laying loose along the frame. Anyhow, I put the following information up on another forum and it is part of my wla build so I will put it up on here as well.
During WWII it became necessary to reduce or eliminate radio static caused by engine interference. In the case of the WLA model motorcycle, early 42 WLA types, such as the early 42 WLA Type III, previous WLA models, and models produced up to about 1944 did not come equipped with radio suppression. 1944 produced WLA models did come equipped with the suppression systems. It became necessary to equip the vast majority of WLA models with the radio suppression systems. The suppression systems consisted of numerous part changes. Below are the parts and pics of parts which make up the wla radio suppression system.

#1600-44 Capacitor, suppression, or spark coil
( Used after U.S.A. Reg. No. 686,726 ) (2)
( 1 used on coil, 1 used on generator )

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#39-26 Terminal, spark plug, later (2)

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#4727-44 Clip, tank to cylinder head bond wire
( Used after U.S.A Reg. No. 694,778 ) (1)

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#4702-44 Wire, bond, tank to cylinder head
( Also listed in WIRING SET HRD 4736-44 )
( Used after U.S.A. Reg. No. 694,778 ) (1)

#025 Screw, cylinder head bond wire
( Used after U.S.A. Reg. No. 694,778 )
( rd-hd., zinc pltd., carbon-S., 8-32NC x 7/16" ) (1)

#0353 Washer, lock, cylinder head bond wire screw
( Used after U.S.A. Reg. No. 694,778 )
( External-Internal teeth, shakeproof, carbon-S.,
11/64" x 1/2" ) (4)

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#1600-42M Suppressor, spark plug (2)

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#1613-30 Wire, shielded, timer (1)

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# I do not know.... coil strap for radio suppression (1) possibly already welded to coil.

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#1743-42M Wire, spark coil & crankcase (1)

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The #4702-44 bond strap attaches to the front cylinder head on the rear right side outer cooling fin. The other end of the strap attaches to the oil tanks return oil fitting threaded stud.

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Earlier wla’s such as mine did not have that type of oil tank return oil fitting with a threaded stud.

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If you reference the 4702-44 instruction tag pic shown previously, It would be at the discretion of the motor pool personal to determine how they would fit the bond strap up to the earlier produced WLA models. The factory did not provide any particular instruction for the adaptation of the bonding strap. One can only guess the ways in which motor pool personal conceived ways in which to adapt the bonding strap. Did some personel weld a stud to the oil tank fitting ? Did some clamp the bond strap to the oil line ? Did some change out the complete oil tank to a later oil tank ? There are many ways the bonding strap could have been adapted. None of those ways would be incorrect as long as the adaptations worked properly. My oil tank just happens to be an earlier produced NOS OEM oil tank. I did not want my adaptation for the bonding strap to look ½ ass, nor did I want to modify my oil tank fitting to incorporate a bonding strap stud. Shown below is what I came up with in order to adapt the bonding strap to my 42 WLA early Type III model. My adapter is a clamping method which clamps to the tank fitting, permits installation of the oil line fitting to the tank fitting, and permits attachment of the bonding strap.

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Now that I had my bond strap adapter made and painted, I restored the fuel and oil tanks so they were ready for mounting. Here is a pic of my bond strap adapter attached to my restored oil tank.

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Here are my restored fuel and oil tanks. Please excuse the poor photo quality. They look nothing like these pics to the naked eye.

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45Brit

Posts: 1416

Joined: Tue Nov 27, 2007 2:29 am

Post Wed Jun 18, 2014 1:58 am

Re: Pa's 42WLA Build

Really satisfying though, when you get beaten-up old tins lime that back into usable condition.

The tanks and front mudguard for my 45 project ( the one with the Shovelhead forks ) will be a LOT of work, but OEM parts... Even for a bike which is very non-standard, but has as many HD parts as I can find and fit in.
Shoot, a man could have a good weekend in Dallas with all that stuff...
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Pa

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Location: Ohio USA

Post Wed Jun 18, 2014 8:43 am

Re: Pa's 42WLA Build

45Brit wrote:Really satisfying though, when you get beaten-up old tins lime that back into usable condition.

The tanks and front mudguard for my 45 project ( the one with the Shovelhead forks ) will be a LOT of work, but OEM parts... Even for a bike which is very non-standard, but has as many HD parts as I can find and fit in.


Satisfying indeed Bro. I've never been a sheet metal person, hating body work the most. But once one takes the time and patience to hit the goal, satisfying is truly the reward.
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Pa

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Location: Ohio USA

Post Wed Jun 18, 2014 9:15 pm

Re: Pa's 42WLA Build

With blackout lighting incorporated onto a wla during ww2, the 4760-44A magnetic generator field switch was added. Below pictured is my nos magnetic generator field switch and the instructions that came with it. Note how this nos kit came with all the mounting hardware.

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The front lighting wire harness would also have been changed out when installing blackout lighting. Both the early two wire and later 3 wire harnesses held the same 4703-41M part number.

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And while I fussed with just about everything in this build I decided to restore my blackout headlight. I took these dimensions because I take dimensions on just about everything. Hope someone can use these dimensions.

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Pa

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Joined: Sun Mar 12, 2000 1:01 am

Location: Ohio USA

Post Thu Jun 19, 2014 7:25 am

Re: Pa's 42WLA Build

Walking and chewing gum at the same time is not one of my standard efficient traits, however, I did much of that while bouncing around parts restoring and researching. My luggage rack shown below before restoration had its issues. Aside from being dinged up and bent, someone in the past had added, what I think was, foot peg brackets. To add the brackets, they drilled additional holes in each of the lower luggage rack mounting braces. I removed those brackets and filled the additional holes. The main mounting holes of the luggage rack were oversize from use so I filled them as well and re-drilled them to correct size and correct location. I made two rivets to replace the original ones where two bolts were now found in the triangular lower mounting braces. I finished the cosmetics and mounted it to the bike. I did not restore it to perfection or an appearance as new. I wanted to leave signs all over the bike of its actual use and character. Though finishes all over the bike such as reparkerizing, cad plating, paint, etc., stand the bike out to the eyes, a dozen rides will remove that kind of new look in those areas and patina will take the new looks place very quickly. Again no restored pics until you see it mounted on the bike.

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Sometime in this bike build, I met up with my friend Tom Faber, also a member on this forum, at Wauseon, Ohio AMCA swapmeet so Tom could take a look at my bent up and dinged badly handlebars. Tom Faber is the best I know in handlebar repairing. Tom looked my bars over and said no problem. Tom resurrected my handlebars to perfection. Below you will see my handlebars after restoring with a fresh coat of paint. I also routed the timer cable, throttle cable, wiring, horn and light switches, and installed the grips.

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