Saving a 1935 Scout case half

[Dusty-Dave]

This 1935 Sport Scout lh case had most all of the threads for the main race retaining nut broken off. I welded and machined one of these once! Never again everything moves and warps when you start in that area. So a new technique.
I turned all the threads off then turned the od to accept a sleeve

I made a sleeve but left enough on the end to thread 2" 16 left hand

Then I made some male 2" 16 left handed threads and parted a nuts worth off with my hightech parting tool.

Then using the threaded sleeve as a fixture I bored the nut to size and cut the left handed thread that acts as an oil seal in this engine.

Then I heated the sleeve to 950 degrees f and slid it into place let it cool and torqued and staked the nut.

Other than the fact it will rust I suspect way better than original and its all straight
Dusty

[TheWhiteDevil]

So awesome to see these old cases saved with some solid craftsmanship

[Kgi4x4]

Yes! Always love the knowledge you share!

[Dusty-Dave]

Dam I just noticed that lots of the broken stuff under the table showed in the last pic. I was kinda feeling like I was making a little progress until I saw that.
Dusty

[Fatkat]

Awesome work Dave

[Madrivermoco]

I want a ‘35 sport scout mountain bike. I know a Chief is easier to find parts for and the 101 is a better bike (and Chout candidate) and the 41 has the skirts but damn...

That 35 rules

[Dusty-Dave]

I want a ‘35 sport scout mountain bike. I know a Chief is easier to find parts for and the 101 is a better bike (and Chout candidate) and the 41 has the skirts but damn...

That 35 rules

Ya oughta start collecting parts, I built this one almost completely out of ebay and swap meet parts. https://photos.app.goo.gl/XHx4DZtkDZGyLdMk8 Don't know for sure but have less than two grand in it. The only really expensive part was the T&O flywheels. Using the 741 cylinders & heads saved a small fortune and the vertical twin frame saved another small fortune.
Dusty

[Bombay]

That is pretty bad ass. good work.

[Dusty-Dave]

The other case half I'm going to use with the 35 left side is probably 39 or later if the pushrod guides are original to it. It had a tiny crack .



Then I discovered that the pinion race bore is well machined just to an odd size that isn't available now if it ever was. So I started making a pinion race with a .0075 oversize OD.
This drill bit in rockwell 45 shaft is all the little Atlas Craftsman wanted even in back gear.

Dusty

[Dusty-Dave]

Forgot to get a shot of boring to size and parting. Boiled the case for 3 or 4 minutes and the race drove in at a medium hammer fit.

Dusty

[Dusty-Dave]

A little better picture.

Dusty

[Bombay]

You boiled the cases in water to get the race in? Thats something new. it makes sense.. Just never heard of it before .

[Dusty-Dave]

Straight out of the WW2 Indian Overhaul manual. A lo tech way of getting about 212 degrees fahrenheit. Bout 209 at my altitude.
Dusty

[Dusty-Dave]

The wife passed last week so I'm trying to keep my head up and find thigs to keep busy so I'm back at it.
With all that welding this is the straightest case half out of this lot. .002 to cleanup after the weld was smoothed .110.

Dusty

[Kgi4x4]

So sorry to hear that! My condolences.

[Madrivermoco]

Dave...

you've been in my family's thoughts an prayers this week. I hope you find some peace and solace.

MJ