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<\/p>\nOn 4\/30\/12, we drove to the DMV in Lawrenceville to obtain our motorcycle permits. After arriving, realizing Alison did not have her 6 point ID, she drove back to Princeton with Sherry’s phone (GPS). She picked up her passport whilst Sherry took the motorcycle test, and luckily, Alison was able to pick up Sherry’s contacts when Sherry failed the vision test at the DMV. Alison got back to the DMV (after Sherry’s phone died and she had to ask someone for directions) and passed her test as well.<\/p>\n
This week we were able to put the clutch back together. Using the manuals, we assembled the larger engine sprocket first. We used our old clutch basket and put the new clutch plates that Glen bought on them. (Glen had adjusted the plates prior to our assembly). We carefully assembled the engine sprocket and used the Allen key to screw the new cup-loaded springs to complete its assembly.<\/p>\n
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Afterwards, we put it onto the case but realized that we would have to assemble the clutch sprocket, place both of them on at the same time with the primary chain in order to put the chain on.<\/p>\n
The clutch sprocket was trickier to assemble. Again, careful adherence to the manuals allowed us to determine which pieces were to be put on first. In the meanwhile, we realized that half of our key was sheared off and stuck in the distance piece of the clutch sprocket. We had put it in in the right keyhole (7 o’clock), but didn’t realize that the key was sheared. We resolved to finish up on Thursday, after Glen made a new key for us.<\/p>\n
On Thursday, we assembled the clutch sprocket with the new key and replaced the clutch basket because our old one had a broken tooth. Adam helped us clean it before we put it on. We also soaked the plates in oil. Afterwards, we put the clutch cover on.<\/p>\n
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Overall, we made many errors but luckily, none were fatal. It was a great learning experience as well as a relief to be doing something other than sanding again.<\/p>\n
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By Week 11 we are getting close to finishing the covers, however it is still does not have the shine of the previous year\u2019s motorcycle. So to take any last roughness of the covers, we finished our sanding in the sink.<\/p>\n
Then, we had Prof. Littman use the Scotch Brightener machine to make it really smooth. Essentially, the machine is a spinning wheel covered in fine grade sand paper. The wheel spins really quickly (3600 rpm) which takes off any final layer of rough metal from the covers.<\/p>\n
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<\/a>\n\t\t\t<\/div><\/figure><\/a>\n\t\t\t<\/div><\/figure><\/a>\n\t\t\t<\/div><\/figure>\n\t\t<\/div>\n\nAfter this, we used a billow sponge and polish to shine the cover. This made the covers really shine and appear smooth to the touch. Glen told us that these covers were much better than last year\u2019s covers \ud83d\ude42 See how they came out!!!<\/p>\n
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We continued our journey in sanding, this time venturing out into the wild (read: E-quad courtyard). Here, Alison showed Sherry the blister on her thumb – popped and painful from sanding so diligently. By now, we had invested our energies and efforts into this sanding project – it became a matter of pride and honor.<\/p>\n
Even so, we wondered that there must be a machine that could perform this task. Alas, we learned that the surface of human fingers could do a better job than an inflexible and hard sanding surface.<\/p>\n
This week we realized how much work we had to complete on the clutch covers. Alison\u2019s cover was not too damaged, but Sherry\u2019s cover had huge gashes in it. In fact, it was so bad that John did not think Sherry would be able to remove all of the deep dents. So, to better assist us in our attempt to sand the covers we requested lower grade, super course sand paper. In our search, we found 40, 180, 360, 400, 600 grade. Below is a picture of the different sand papers we used.<\/p>\n
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To get the smoothest results for the cover first use the lowest grade sand paper, then move to a higher grade sand paper. As the grade number used increases the cover becomes smoother.<\/p>\n
By the end of this week, we noticed considerable improvements in the cover; many of the dents were gone or faded. However, now the cover seemed rough and uneven, so for next week, we have to start evening out the surface, and then use the finer grades (higher numbers) to give them a smooth finish.<\/p>\n
We also made our presentation on Thursday.<\/p>\n
Clutch-and-Chain<\/a><\/p>\n Size<\/b>:\u00a044.8M\u00a0bytes\u00a0Modified<\/b>:\u00a01 May 2012, 16:17<\/p>\n Since our disassembly of the clutch was finished, we sought out other tasks. These included sanding the headlight piece, which was a half of a hollow sphere.<\/p>\n Then we picked up a bigger task, which consumed a great amount of our time in the class. We each took a cover: Alison took the transmission cover and Sherry took the clutch cover. These cases contained many deep scratches and cuts that needed to be sanded out. The clutch cover from the original bike wasn’t in good enough condition to use again, as there was a splotch of glue on the inside. Chris took us to the storage shed and we picked out another clutch case that matched ours.<\/p>\n The pictures of the covers before sanding are shown below:<\/p>\n <\/p>\n After sanding minimally with grade 240 sandpaper, we quickly moved on to higher grades. Professor Littman explained to us that this was not a simple task, that it would take us weeks to do it right. Even though we complained, we got down to business.<\/p>\n Today we got to drive the Model T!!!!<\/p>\n <\/p>\n Prof. Littman explained that the Model T transmission is very similar to our Tiger Cub transmission so we decided to do a little research about the\u00a0clutch and how it is similar to ours. Below is a picture of the Model T clutch.\u00a0When the spring is pushed to its full pressure, all the small and large\u00a0discs are fully engaged – this is characteristic of high speed\u00a0gear. In\u00a0order to reach high gear,\u00a0the emergency handbrake must be pushed to the furthest position.\u00a0(http:\/\/www.modeltcentral.com\/transmission_animation.html<\/a>)<\/p>\n Then, in the lab we were preping the gas tank and the head light cover for painting. Specifically, we were trying to remove all of the rust. We used the wire brush and emory paper to do this. Although this task seems easy, it took a lot of time to make the covers smooth and get rust from hard to reach areas.<\/p>\n We decided the best way to proceed with the clutch inspection was to measure the different parts. We used The Triumph Workshop Inspection Manual as a reference. These were our findings:<\/p>\nWeek 8 — 3\/27\/12 & 3\/29\/12<\/h3>\n
Beginning to sand<\/h4>\n
\n\t\t\t\n\t\t\t\t<\/a>\n\t\t\t<\/div><\/figure>\n\t\t\t\n\t\t\t\t<\/a>\n\t\t\t<\/div><\/figure>\n\t\t<\/div>\n\n<\/p>\nWeek 7 — Spring Break<\/h3>\n
We did nothing.<\/h4>\n
Week 6 — 3\/15\/12<\/h3>\n
Drove the Model T and Cleaned the Gas Tank & Head Light Case<\/h4>\n
\n\t\t\t\n\t\t\t\t<\/a>\n\t\t\t<\/div><\/figure>\n\t\t\t\n\t\t\t\t<\/a>\n\t\t\t<\/div><\/figure>\n\t\t\t\n\t\t\t\t<\/a>\n\t\t\t<\/div><\/figure>\n\t\t<\/div>\n\n<\/p>\n<\/p>\nWeek 5 — 3\/8\/12<\/h3>\n
Making measurements and helping the frame group<\/h4>\n