Featured T595 Complete Rebuild (okay, Maybe Not "complete Rebuild")

Discussion in 'Builds & Projects' started by Jugg, Sep 21, 2021.

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  1. joe mc donald

    Subscriber

    Dec 26, 2014
    13,693
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    slough / burnham
    Jugg
    You are the only person that can decide that. Either way you or some newbie gets a good as new steed. All thanks to you.
    Joe.
     
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  2. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    So thinking that the drum was wrong was close. Turns out what the issue was, is that the 2 arms that hold the drum in position for each gear are cranked in opposite directions and I put them on the wrong way round, so that flat on top of the star was where I thought neutral was and it was sitting 180° from there but there's a cut out on the back of the star at the bottom left that is actually neutral. So that's why I thought it was between 5th and 6th. Happy man now. Hopefully get it back together and in the bike before the weekend is out
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  3. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Gearbox all sorted out, changes properly now and finds neutral no problem. Got the crankcase halves cleaned up, sealed and re-torqued again. Just need to get the sump and clutch back on and can get it back into the frame again, hopefully for the last time!
    20220407_212414.jpg
     
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  4. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Oh well. That's the past 6 months down the drain. Mounting the engine back in the bike and fucknows what happened but the crankcase split at the motor mounts, done everything the exact same as I did the first time pitting it in but something must not have been right. Have a boy that does homers for welding it but I think the amount of heat going through it will distort all the bearing locations. Will see what I'm thinking when I calm down.
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  5. Vulpes

    Vulpes Confused Member
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    Mar 14, 2018
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    Well, that is harsh, you certainly did not deserve that after all that excellent work - I hope it can be resolved, mate. :pensive:
     
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  6. Clarkey231

    Clarkey231 Noble Member

    Jun 9, 2016
    460
    313
    Exeter
    Ah Jesus sorry for you. Not commented before but enjoyed your build. Hope you can sort it!
     
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  7. TRIPLE X

    TRIPLE X Active Member

    Sep 1, 2021
    55
    28
    Downham Market, Norfolk
    That's really bad news after all your hard work. Are all the shims between the engine and frame correctly installed ? And there is usually a tightening sequence for the engine bolts ?
     
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  8. sprintdave

    sprintdave Nurse,he's out of bed again

    May 25, 2014
    1,331
    750
    Birmingham
    F**k, f**k, f**k, that is so shit luck after all that hard work. Feel for you.
     
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  9. Iron

    Iron First Class Member

    Dec 29, 2021
    2,114
    643
    Bob Ross Studios
    Oh bloody hell. Sorry mate, that'll keep hurting and will be stinging in the morning too. Pooh bear bum holes. :(
     
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  10. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Well, you are bang on the money, just been out to the shed and I've missed out the shim between the frame and the engine. That's one way to spoil a weekend. What an idiot
     
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  11. Wessa

    Wessa Cruising

    Apr 27, 2016
    10,507
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    North West England
    Really sorry to hear you bad news. I hope you can find a resolution mate…
     
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  12. Wessa

    Wessa Cruising

    Apr 27, 2016
    10,507
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    North West England
    Really sorry to hear you bad news. I hope you can find a resolution mate…
     
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  13. Jet City

    Jet City Noble Member

    Sep 24, 2018
    493
    313
    Seattle, Washington USA
    Noooooo. That is not how I wanted this thread to go. Sorry about that, man. o_O:(
     
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  14. DCS900

    DCS900 Careful, man! There’s a beverage here!
    Subscriber

    Sep 11, 2021
    2,331
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    LA
    Hope your welder turns up trumps… you really been in a journey with this one!
     
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  15. Hubaxe

    Hubaxe Good moaning! aka Mr Wordsalad :)
    Subscriber

    Mar 25, 2020
    1,678
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    Aix Les bains - French Alps
    That's not much regarding all you've brilliantly done already. Just a last inconvenience before the back to road step.
     
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  16. joe mc donald

    Subscriber

    Dec 26, 2014
    13,693
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    slough / burnham
    Jugg
    O'H boy how i feel for you after all that work. Any chance of getting it welded. And we all have done the same at one time or another. I built an a65 engine and forgot the crank shim washer. Luckily i didn't do to much damage but just goes to show you we are all human and we do err sometimes. I know this is of no comfort but i do feel for you.
    Joe.
     
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  17. TRIPLE X

    TRIPLE X Active Member

    Sep 1, 2021
    55
    28
    Downham Market, Norfolk
    Jugg,
    Don't give up now. We all want to see your project finished and back on the road in fine fettle :worried:
     
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  18. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Thanks for the words of encouragement folks, much appreciated

    Haven't gotten a chance to get the engine split again as I've had a busy couple of weeks but spoken to the welder and he is going to sort it out for me, thank christ. Will hopefully have a better update in the next week or so, fingers crossed

    I WILL NOT BE DEFEATED!!!!:joy:
     
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  19. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Finally got out to the shed after a busy month. Engine out and on the bench.... AGAIN!! And hopefully for the last time! Got the crankcase split and the gearbox selector all stripped out of it so it's just the bare casing left. It's obviously bad because it's in more bits than it should be but I think it should be salvageable. My mate sorting it is a shit hot welder so I have every faith. Just need to give it a quick clean and get it across to him tomorrow night hopefully.
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  20. Jugg

    Jugg Senior Member

    Mar 22, 2021
    424
    113
    Aberdeen
    Crankcase dropped off, just to wait and let my saviour work his magic now. Hopefully get it back by Wednesday next week if he can squeeze it in
     
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