I sent a pic of the carnage to Craig Hansen and he said they had tried resurfacing the cast iron bit BITD and it just didn't work. I can see that--hard to fixture it like an automotive flywheel.
Right now, and for the next couple weeks, is perhaps my busiest time of year for work but paradoxically I get more done because I make a point of stepping away from the desk and into the shop for an hour or so every day. So here's about a week's progress:
I put the trans in my adapted VW engine stand for clean-up:
Scrubbed it all over with a 'red' Scotchbrite:
I took it outside and sprayed it down with etching mag wheel cleaner, then after some more cleaning gave it the soft Scotchbrite finger painting method to get to here:
I did the clamshell also. Left is mostly finished, right is after red SB and mag wheel cleaner:
The method is spraying some silver alu engine paint onto a green Scotchbrite pad and using that to apply the paint. It basically puts paint into the pores while leaving the metal mostly bare.
Nice shiny clutch bits got mounted:
This came up here or on another board. New driveshaft boots are being made with worn-out molds, so the installation directions aren't as clear. Left is brand new, right is from 1979:
Oben is German for 'over' or 'top.' They're also marked for which end goes to trans. Old on the left this time:
Getriebe is transmission, seite is 'side.' Getriebeseite is on the same side as the 'oben' marking. I'm going to be reusing the boot for now as I expect the whole bike is going to come apart for a lot more work after I get addicted to the RS experience.
I've never liked the pin that holds the clutch actuating arm on /6 and /7. It looks like something that wants to fall out. So here's what I do instead:
That's an M8 x 60 screw, a couple spring washers (because German), and a plain nut and a Nylock to jam against each other. Installed, looks like this:
In a perfect world the shank would be closer to a true 8mm and the threads would be shorter but I've run similar on Ernst for over a decade.
The trans is mostly in:
I stopped here for the big work as I was in no mood to deal with the driveshaft bolts but I had a bit of time to change the shocks. Here's old and new:
The shafts on the old shocks are rusty and pitted. I have a fantasy that there's a way to rebuild them as I'd like to keep the vintage mods but I jumped on the Hagons a while ago just in case. Mounted up:
Next steps are bolting up the driveshaft, remounting the battery box and battery, bleeding the front brake that my /6 is loaning, swap the rear wheel with the one from my /6, and do the rest of what needs done to hear it roar again. It could be a few days.