Small Hirth engine & last build...

[yellowlab2]

You da man, Dan! Looking forward to seeing the rest of this current build!

[ruppluver]

I'll be using a 72 end fill gas tank in this build.The
question is,did they change the location of the gas lines
& not cut slots for the tank straps in 72,73? In the 70,71,
they had cutouts for mounting straps & gas lines were offset
to the left on tank to clear the handlebar mount/bar shaft.Just
curious.

[ruppluver]

Pulled some more parts off,cleaned them & painted them.I don't think I'll paint the gas tank.It looks pretty good the way it is.Tomorrow I will cleanup & hopefully paint the handlebar support.Thats the only thing I have to do.

[ruppluver]

Finished sanding off ALL the old paint & primer!!
This needs lots of work,good thing I'm not in a hurry.

Looked through my Rupp ski stash,looks pretty bad!! BUT
I did find an NOS pr of Scorpion skis?? to modify.I had
to cut off the front spring/shock mount.

Will weld this Rupp spring mount on,will mount shocks,
off to the side & fasten other end to the spindle/saddle
mount bolt. Oh,I'll also cut off the rounded part in
front,where the ski loop attaches.I'll use the ones already
on the skis!!!

[ruppluver]

I have been working on the skis. Got the Rupp front spring mounted & wear bars made for both skis. Will sand & paint in the future.NO pics yet.

[ruppluver]

Today I finished up the welding & finished marking shock mount location,clamped it to ski & drilled it. Also sanded & primed skis.Will paint really soon. I also marked,drilled & riveted the underside of tunnel spring,tension mount. Using the back of tunnel like Rupp did,didn't put enough tension on track/suspension.Should be ok now.Later.

[ruppluver]

Skis done & on sled.

Shocks hooked up to offset spindles.

Side shot of sled.I'll eventually get it done.

[ruppluver]

Yup,painted the gas tank two tone,black bottom,blue\gray top.
Black is automotive paint,the blue/gray,is used on rebuilt
electrical motors.The Yamaha guru,"woodchuck",owns a motor
rebuilding shop,has many cool colors to pick from.He suggested
I try this color on my sled.

[ruppluver]

I worked outside today,out in back,cleaning up branches & leaves;dumped it all in the garden=big fire,later!! So,tomorrow,depending on the weather,I will work on the lower front panel,this is top priority. Everything else gets put on hold.

[ruppluver]

Started on my new wiring harness today,got coils &
spark plugs wired. Also ran it a very short time on
sprayed gas,starts ok,timing really helps. It will
have an ON/OFF switch for power,lights will go through
regulator & will be ON all the time.Don't need all the
un-necessary wires!!

Also found a DIFFERENT steering setup!!! It will use
a 73 shaft & adjustable JD handlebars.Will clean off ALL
the rust & chrome, then paint it. Should work just fine!!

Also found/made the wires for tail lite,got those run!!

[ruppluver]

Using 73 steering stuff.

Had to shorten up handlebar shaft.

Had to weld up holes & re-drill new holes in the plate
on hub,to accept JD bars.

I put JD bars on to see how they would look.Might
be ok,I don't know.I'll put the seat on to see where
the bars will end up.I'll straighten dash out later.

[ruppluver]

I put upholstery on rear compartment,also set seat in place.Will
put seat snaps on next.Today I pulled the bulb out of the housing,
replaced it with an LED 5 watt bulb. It does NOT get hot,should
work ok.

Put handlebars in place & adjusted them.Yup,will be just fine.
This fun sled is coming along just fine.I also made a fiberglass
piece to cover up the center of the box on bars.Will paint it same color
as the bars.

[ruppluver]

Sanded the whole panel,then brushed on some PolyAll 2000.
Will let it dry a few days,then sand it ALL off. I stop
with the repairs,when I decide it's good enough for a
trail sled.It meets that criteria now!!!!!!!! It's
NOT a show sled,so I'll leave a bunch of flaws in it,
you can look for them later,if you want.

[ruppluver]

Yup,time to work on exhaust.Partially wired in place,
set on some 2x4's to get the right height.

Trying to fit hood.Had to try 2 bumpers to get one
that would fit hood ok.

I think I'll open up the louvers at the back.Will need
some air flow under hood. The air will help cool
the muffler & brakes,maybe!!

[ruppluver]

Finally had time to work on the exhaust.Yesterday,I cut,fit
& welded it together!!! Also painted it,but got paint a tad thin.

Today,I cut,fit & welded the short stinger pipe,yup,out
the side!! I couldn't go down,the sled dolly would hit it.
Will trim it later,after panel is pre-fit.Cutting the hole
in the lower panel will be fun,if I make a mistake,at
least I can repair the fiberglass!!!!!

[ruppluver]

Bottom panel painted "Dan's" blue!!!

This pr of "free" handlebars,were picked up at the
Milbank,SD swap in June.


Exhaust done & installed,lower panel installed.

[ruppluver]

www.flickr.com/photos/37481125@N02/36545799642/in/datetaken-ff/
Video of this engine running.

[drrupp]

Looks great Dan. What do you have against Rupp Red?

[ruppluver]

Red is ok,but I wanted a change on this sled.It's the last sled I build,I want it stand out in the crowd!! LOL.

[ruppluver]

I'll wait to finish the hood!! It's a rider for sure this winter.