Concours 2

More bikes:

Chico Concours 1

We took Freddy down to the Chico Concours this morning. Here are a few snaps. Starting with bikes:

DKW 125 Gas Tank Petcock M12x1mm

Sorry for the attention grabbing headline.  I've realized my blog subject lines make for good google searches, for obscure shit like petcock sizes on motorcycles.  In this case, the petcock size for a 1971 DKW 125 Boondocker is a M12x1mm thread.  Happens to be a very common moped size, so I picked up two part# 50294 petcocks from 1977mopeds, which fit a Honda Hobbit.  Perfect fit on the DKW.

As you can see, I've started assembly work on the bike.  Spent the past few weeks painting and polishing and cleaning up random parts.  Trying to take my time.  As such, I've discovered the back porch to be a much nicer place to fiddle than in the garage.  I can eat lunch outside, and spend 10 minutes doing odd jobs.  

The petcock money shot is at the bottom.  

Even More Freddy Updates: It Runs

As the title suggests, the freshly rebuilt transmission is installed, and it is exceptionally quiet and smooth.  Newly rebuilt front suspension is also very smooth and creek and groan free.  Those old bushing from the 1980s were pretty dry rotted.

More Freddy Updates

I got the new trans installed a few evenings ago, then managed to get the engine in this morning.  A few shots below, also showing the freshly painted engine and cleaned up engine bay.

Freddy Updates

I have been doing some work on Freddy since I snatched the engine out.  I spent a day degreasing, then decided to remove the entire front suspension and steering rack, in order to properly paint the engine bay.  That then led to a full cleaning and repainting of those components.

Cleaned up and painted the a-arms.  Lower bushings were fine, but upper bushings needed replacement.  Decided to just go with regular rubber, as I really don't have plans to race him, so no need for urethane.

My rotary tumbler from Harbor Freight has proven to be one of the more useful tools in the garage.  Just throw in a handful of hardware, a little degreaser and water, and turn it on.  Come back an hour later, and everything is nicely cleaned, with a lovely surface finish.

Engine bay cleaned with a light/medium grey.  Gets rid of the blackhole look, so hopefully it will be easier to spot leaks or grunge.  

Freddy Engine and Trans Removal

I decided to use this long weekend to get started on removing the engine and trans from Freddy.  Despite only having about 1,500 miles on the trans since it was installed in 1992, it's very grumbly in 3rd and 4th gear, with a lot of noise under gentle acceleration.  So I put on my grubbies and boned up on my favorite cuss words for this messy task.

Engine removal was pretty straightforward, except for the starter.  One nut and one bolt that are pretty impossible to get at with normal tools, especially since Freddy uses lower motor mounts.  My new load leveler engine brace worked great, making it very easy to the engine up and out.

Removing the transmission was also fairly easy, until I actually had to lift it out.  Snatching 76 pounds from ankle height up to chest level, and then stepping over the radiator and front support while still holding it at chest level was a task.  As my neighbor can attest to, I apparently screamed out "damn dirty whore" in the middle of that motion, giving me the inspiration I needed to complete that task.

Best part?  Finding about five pounds of rat shit littering the engine bay floor.  This is going to be a fun cleaning job.

 

New Tools and DKW Work

I splurged on a few new tools for upcoming projects. One is 1/2" sander that worked great this morning. Very easy to use in tight spots, easy to change belts on etc.  

I also picked up a load leveler, which I'll be using as an engine hoist for pulling the motor out of Freddy, in preparation for swapping the transmission. Seems fairly robust, and just the right size.  It's also adjustable so you can tilt the engine one way or the other while it is suspended, in case you need to wiggle it a little bit.  My old "hoist" for the FV motor was a pair of straps, and any wiggling meant wiggle by armstrong, whilst trying to keep things from crashing about.

I haven't posted much about the DKW project, since I've been working on Freddy. But this weekend I finished up all the welding and metal cleanup. It will only require s little bit of body work to fill in a few nicks and scrapes. The new 1/2" sander worked great for getting into tight spots.

Meyers Lemon Martini

A refreshing martini to enjoy while I watch a little golf. Fresh squeezed Meyers lemon, mint and basil before a quick shake.

Comparison

I parked next to a CRZ yesterday, whilst at OSH getting a new toilet flapper.  One of these two-seaters moonlights as a minivan on weekends, by the size of it.

Fog Lights Installed

I treated Freddy to some Hella 500 fog lights over the weekend.  Install was fairly easy, once I cut a little metal out of the way that held the old rectangular turn signals in place.  These units fit perfectly in the grill opening, between the tow bar mounts and body work.

Wiring the fog lights was easy enough, once I sorted out the fuse box under the dash.  The original owner, Fred Champion, must have added some lights or speakers to Freddy at some point, because there were several "spliced wires" under the dash that were simply two ends of wire twisted together, with no tape or crimp on connections.  All sorted now.

I also mounted the small LED front turn signals to the front grill bar.  You can just see them in the picture.  Being LED, they didn't draw enough current for the stock flasher relay to activate.  So no blinky blink.  But luckily Pep Boys carries multiple types of LED Electronic flasher units, that literally plugged into place.  Overall, I think it is a nice clean look.

 

1968 Saab Sonett II V4 - Fast Freddy

It's about time I posted about my recent acquisition, Fast Freddy.  A 1968 Saab Sonett II V4, that's been in the family since around 1990 or so, previously owned by Fred Champion.  Fast Freddy was our autocross car during most of my High School and College days, and was in fact my High School senior project.  Stepbrother Mark purchased it from Jack about 10-12 years ago, and apparently drove it maybe 500 miles in that time period.

The past month I've spent most of my time getting Freddy back in condition for road use.  The stock gas tank was horribly rusted, so I just got done installing the 5-gal aluminum tank we used for racing, along with new filters and hose throughout.  Freddy can actually make a long pull in 3rd and 4th gear, without running dry of fuel!

Other than that, I've done lots of other projects, like converting it over to a coilover sleeve suspension setup, making a new exhaust, and installing a new interior upholstery kit.  He's coming along nicely, and is of course very fun to drive.  He's still a little loud, so I'm going to revise my exhaust design with a pair of "turbo" style chambered mufflers I found.  They only measure 3-1/4" thick, which is actually thinner than the glasspack muffler under the car now.

After that project, I'll probably turn my attention to the engine bay, and start doing some clean-up work.  Freddy was always a race car, so he's just sorta grungy right now.

Pics as of now, sitting on his new Rota RB wheels:

front suspension setup, new coilover sleeves buillt

Grungy fuel filter, after only 20 miles of use

5gal AL tank installed, new smaller battery, new smaller spare tire

rear coilover kit I built

rear installed