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Old November 13th, 2008, 12:22 PM   #41
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I also have a F head T90, but know it needs rebuilt too.

T90's howled bad originally, it is because they have straight cut gears. PM sammy on earlycj5.com (IIRC he is on the 2apage as well) and listen to his first ride, his is REALLY loud.

and yes, 18's leaked form the factory, good luck sealing it up totally, after Adam resealed mine the last time it lasted a week driving it

The way the shims are it seeps out.
The F head t90 would be a nice upgrade if you want a little more gearing as it has a lower first and a slightly lower second gear
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Old November 13th, 2008, 02:37 PM   #42
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good to know. i have two 41's on the trailer for parts.
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Old December 6th, 2008, 04:36 PM   #43
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more updates on the project. last saturday when it was warmer i was able to get the primer sanded and second coat on as well as a first coat of o.d. on the tailgate passenger fender and the grill. I also got the starter and bracket pulled cleaned, stripped and repainted. I got the fan stripped and repainted too.

I still had plenty of leather that I made the trans cover gasket out of so I cut and tanned some leather for the pads between the fenders and the grill & frame.

Today the project was to get the new radiator installed and the starter installed.

Old radiator removed and the front crossmember painted


Installed the refinished fan with button head stainless fasteners



After the old radiator was drained and out I removed the petcock from it and cleaned it up for installation on the new radiator



The rubber radiator pieces were still in very good shape so I cleaned them and reused them


radiator installed






Starter



Headlight Bezels and jerry can holder with some paint

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Old December 6th, 2008, 05:18 PM   #44
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Lookin good, do you plan on painting the L Head engine too?
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Old December 6th, 2008, 06:27 PM   #45
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Lookin good, do you plan on painting the L Head engine too?
thanks. yes satin black with silver accent pieces when it gets rebuilt.
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Old February 21st, 2009, 08:49 PM   #46
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back to work on yancy again finally.
first I got the stainless nust, bolts, washers, stainless wire clips, extra cloth wire loom, and the new grill top welt kit.



new ignition, light switch, foot starter and light fender junction.


new wiring harness, tail lights and parking lights




new alternator and refinished bracketry installed


old bumper removed


new bumper test fit


front frame stripped, primed and painted


removing the black ]coating on the front bumper



next I will get to removing the trans crossmember for strip and refinishing and start to pull all the old main wiring harness when i get the coil confusion remedied.

Last edited by ovrlnd; February 21st, 2009 at 08:54 PM.
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Old March 6th, 2009, 01:04 PM   #47
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Last weekend/week it was time to remove the master cyl. and do a rebuild. it appeared to be leaking from the rear piston seal so out it came

before:












rebuild kit arrived just in time



some of the last grill work here.

installing the new grill to hood welting





test fitting that



on to installing the grill to radiator welting from beachwood canvas with stainless steel wire and the new parking lights and grill harness.






Images of the grill on the bench after



and how it looks bolted to the front of yancy


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Old March 6th, 2009, 02:05 PM   #48
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lookin great
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Old March 6th, 2009, 02:16 PM   #49
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Looking great!

Why did you use the Normandy star? Just preference?
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Old March 6th, 2009, 02:32 PM   #50
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Looking great!

Why did you use the Normandy star? Just preference?
yes the star was a preference call. stencil wise I would have much preferred to not use as that circle was a p.i.t.a. to cut out. I cut some paper versions of the various stars and we laid them on the hood. it was the one that my dad and I could agree on.

part of this refurb is for my dads father, and great uncles hence the army theme. the uncle on my moms side served in the 34th in italy etc... and all from my dads father fought in the pacific from the start to the end. not wanting it to be overly specific (and that it is a 2a) we decided on the mil. theme.
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Old April 11th, 2009, 09:14 PM   #51
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I have been making good progress. there was a small setback with the master cylinder leaking from the copper washer between the Y fitting and the m/c. I had put two new washers in there to no avail. I had to pull it back out and found what I believe was a casting flaw and caused a section of the sealing face to be raised. I took some fine emery cloth and flattened the area, cleaned it, annealed the washers, put it all back together and bench bled it again and waited for leaks. none formed so I put it back in and it has not leaked a drop since.

I removed the transmission crossmember and striped it and repainted it along with the trans plate and scrapped the gelled trans mount bushing for a brand new unit. the transfer case bushing was in nice shape so it got cleaned up and reinstalled. a few days later I put that back in with all new grade 8 bolts.



I also removed the clutch pedal arm and both pedals for refinishing. I have all new return springs for the arms when it goes back together.




Then it was time to remove all the existing wiring



I needed some room before starting to re-wire so I figured it was a good time to pull the air cleaner assembly and refinish that with it's brackets. I was in overall good shape but there was an oil tube added which i removed and welded up. some minor rusting on the top of it and there was some bondo on bottom pan. I removed the bondo on the pan and discoverd a few holes. I tacked them up from the inside and sealed it with JB weld and sanded smooth and perfomed a 3 day leak test which showed no problems. I then stripped the entire cleaner and hit the top with some high fill primer and sanded that to fill the pitting smooth. Primed the unit with black primer and then painted it with black semigloss engine enamel. The pics don't really do it justice but I am really happy with the results and it looks fantastic.








Then it was on to start the rewiring. I went to install the fenders and it was then I realized that I had ordered the wrong size stainless bolts for the fender to tub, so i used some of the fender to grill bolts to get the fenders in place and lined up.





for the grill mount wire clips I tapped the hole in the grill tab to 1/4-20 and fastened them down with a stainless socket cap.


then pulled out the hi beam foot switch out, cleaned it on the bench wheel and connected the wires then reinstalled with new stainless bolts and washers.



then marked, drilled and mounted the fender junction block. I decided that on any of the bolts running through the fenders or firewall I would use button heads and acorn nuts with the lock washers. It looks really nice.



routing the harness along the fender





wiring up the new light switch


then installed the battery for fit and to take measurements for the length of battery cables I'll need



then got on finishing up the tailgate.


mounted up the jerry can holder. I used 3/8" stainless bolts with neoprene washers between the holder and the tailgate.






and finally installed the tailgate footman loops.



stay tuned for more.
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Old April 22nd, 2009, 08:20 PM   #52
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last saturday I worked on getting stuff wired on the passenger side of yancy. not finalized yet as I didn't have enough cloth loom for the negative cable so once that comes in I can install it. got the ammeter and the fuel gauge back in and in the correct location and got the foot starter switch installed. not a whole lot to shout about but necessary stuff none the less.

the coil that was on there is for use with an external resistor. I thought about reusing it. then I changed my mind and am now just going to run an internally resisted coil so I do not have to muss things up with a bypass wire and resistor making it a cleaner look. so it's back to waiting on parts.

routing the cables and marking for length





my daughter wanted to help make the cables. we stripped the wire end and she operated the torch while I fed in the solder. then she used the heat to shrink the heat shrink tubing over the seam. she was excited. (this is a poser shot, hence the lack of safety gear)


the finished starter to foot switch cable


working on putting the dash back together and wired. we got the 2 guages back in and wired, opened the original key location and put in the ignition switch and high beam indicator.




I ended up making my own pedal draft pad set. my springs were fine so I cleaned them up and painted them and got some neoprene and stainless fender washers from the hardware. looks good and very inexpensive.


Last edited by ovrlnd; April 22nd, 2009 at 08:29 PM.
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Old May 2nd, 2009, 09:57 PM   #53
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this week and today I got a bunch of work done and in the next few weeks making some big progress. thursday I dropped off the rims and passenger seat frame off at the stripper. the firestone ndt's should be here late next week as well.

yay, new parts


new air horn


Installed the new crossover tube and plug wires



new cork gaskets for the oakes air cleaner from beachwood canvas.




making new line for the oil pressure gauge



on the copper tubing after I cut it I like to lower it in the fixture and file it flat even to the fixture to get a nice flare. then cut off the nice flare and do it over because I forgot to put the fitting on.


making the wire from the ignition to the coil


alternator wire and routing of wires on the passenger side of engine bay




new fuel pump to carb line. pretty neat as I got this at autozone and it was o.d. green.
I moved the fuel filter underneath on the line from the tank.


since I am rewiring I wanted to get some items returned to normal and the first thing I tackled was the horn. I removed the column plate and the column tube



I removed the old horn parts down in the worm tube.
then fished through the new horn assembly wire. I did this by pulling a length of mason string up the worm shaft and taping it to the new horn wire then pulling it back through with ease.



put the new horn where it will go.



then I had to install the contact on the outer tube and my tube had no cutout. so I measured and cut the hole for the contact and tapped the mounting holes to 8-32.




refinished the column tube clamp

but I am still waiting on the new upper column bearing to arrive.

working on the driver seat

Last edited by ovrlnd; May 2nd, 2009 at 10:02 PM.
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Old May 20th, 2009, 08:50 PM   #54
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more progress. finishing up the wiring to get everything working. and starting to get things back together in hopes of getting it down to my buddies shop for some trans and driveline work. getting really close to firing yancy back up and getting excited. I got the passenger seat back from the stripper and the back pan is really pitted, thin and in worse shape that previously thought so i plan to order a new back pan to replace it completely.

pics of the routing of the brake lines off the master cylinder



running the rear harness



the refinished steering column


new upper bearing in the column. this really fixed the major slack from the old worn out bearing.


Refinishing the steering column bracket



steering column reinstalled with wheel


the horn button, works great beep beep.


gauges back in


tail lights on and working


parking lights work


headlights work, high beam switch works and the high beam indicator light comes on like it should


air cleaner back in with the new stainless clamps


Passenger side lower fender bolts back in


Rims



Thanks to my buddy bob at cruisers candy shop who is a coker tire dealer got me the Firestone ndt's and tubes for a great price.



so I am going to try and get the tires mounted up this weekend and get them on, install the clips for the battery cables, and get some connectors to finish up the tail lights/rear harness.
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Old May 23rd, 2009, 07:08 PM   #55
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I got the ndt's mounted on the rims. and got them on yancy. man what a difference in the looks!!!. really glad I got the 7.00x16 size with the 1" springs I installed. got the wipers connected to the ammeter for power and put the light switch in the dash leaving only a few small finishing touches to wrap the electrical up I hope. I also put the pedals back in with all the new hardware.




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Old May 24th, 2009, 07:55 AM   #56
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Very nice!
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Old June 4th, 2009, 09:34 PM   #57
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I can't wait to see it on a Grayling tank trail this fall.

Nice work
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Old July 1st, 2009, 06:33 PM   #58
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Wow- Lots of work and lookin' great! Cool.
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Old July 1st, 2009, 07:28 PM   #59
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Love the stocker, wish mine was worth saving!
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Old July 1st, 2009, 07:36 PM   #60
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Wow the tires look awesome, oh and so does the 2a.

If you wouldn't mind PM'ing me what the tires cost and some contact info? I need some for my btc-3
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