Bird Engineering Baja Build/Restoration

[Mrmonk7663]

Installed the billet flywheel. It appears that my Mod2 cam is defective. Engine will not rotate fully. This has been documented in the main discussion area. On hold until this gets worked out. Very frustrating.

Flywheel install was a bit harder than the magical edited YouTube videos show. The stock key did not come out without a huge fight. I got it out though and lapped, cleaned and installed the flywheel but had to take the sidecover off to diagnose the cam issue. In limbo until tomorrow as the vendor is closed today.

 

[JTSpeedDemon]

That really sucks.

 

[Mrmonk7663]

Yes it sucks but hopefully I get a resolution tomorrow. My head isn’t done yet so right now I’m ok time wise. At least the cam is a quick swap when I get it resolved. The more time consuming engine stuff is done. Tonight I’m going to clearcoat the seat backs. I’ll get some lictures if that and the low profile flywheel this evening.

Ordered another side cover gasket to be ready for when the cam situation is fixed.

Also picked up a YerfDog 3002 frame last night

 

[Mrmonk7663]

Billet Flywheel pictures as promised. Tearing apart the engine I can see how the additional support of the billet sidecover would be beneficial. A bit pricey though. I’ll grab some pictures in a bit of the seat progress.

 

[Mrmonk7663]

A few more things tonight. On the side of the Baja where the jackshaft sits was a factory welded guard for the stock torque converter. It accommodates a 6” Pulley. With the engine I’m building projected to be around 14-15 hp, a 40 series might be necessary for optimal performance and for belt life. So I lopped off the factory guards.

Next I drilled my seat bracing in preparation for the seat install. I needed to knock that out before powdercoating. I think the kart is ready for powdercoating and blasting now...I’ll give it a once over tonight to make sure I’m not forgetting anything.

Continuing, a couple pics of the seatboards. 1st layer is black spray paint. 2nd is an expensive furniture paint. It’s a very durable paint designed for contact and friction. I’ve used it on benches I’ve made and it holds up to the chikdren’s Antics awesome. Last coat is a rusoleum clear coat with UV protection. Boards will be mounted with 1/4” T-nuts. Seat cushion will be attached with heavy duty outdoor Velcro. Once kart is done with PC I’ll mount the seat and cushion and provide pictures.

Finally, last picture is a cool touch I found when rubbing the riveted plate on seat upright with acetone...

 

[JTSpeedDemon]

Keep that ID plate!!!
That's cool, my kart was the kind with the little sticker.
Needless to say, it's missing.
At least the kart's ID'ed though.

 

[Mrmonk7663]

Yes indeed. The plate is staying for sure.

 

[Mrmonk7663]

The Baja has been dropped off for powder coating. Should be done late next week!!

 

[JTSpeedDemon]

What color will it be powdercoated in?

 

[Mrmonk7663]

Satin black

 

[JTSpeedDemon]

Someday I would love to get our ol' Birds together! Maybe, just maybe, since you're in Houston....

 

[BigWes]

Just out of curiosity, how much does a PC job cost? You can PM me if you don't want it to go out on the main forum.

 

[Dingocat]

I wanna know too plz... thx

 

[Hellion]

Satin black

How original.

 

[Mrmonk7663]

Sure JT...that would be fun.

Alright cost...so I dropped off two things as seen in the pictures. One is the Baja the other is a seat frame from the 30032 I picked up.

Both pieces will be sandblasted. Estimated time to blast both was 2 hours. 1.5 for the kart and .5 for the seat piece. If it goes over then it’s on the guy not me.

Powdercoating-2 layers. First layer will be the satin black and the 2nd will be a powdercoated clearcoat (this was optional, and was an additional 30% of the powdercoating portion of the bill)

Total for everything including blasting and state sales tax will be $370. One one hand it’s not that expensive, on the other hand it’s 3 times what I paid for the frame.

The reason I chose powdercoating for the Baja though was age. The Baja being dang near 40 years old, I want to protect it. The Spiderbox I have had factory powdercoating. It still looks decent after 10-15 years of abuse and weather. With care and a garage, the PC on the Baja should last forever.

I won’t be doing this to the other karts, but for the vintage kart I had to splurge

Hellion...the satin black is going with the “Murder Baja” monicker/theme

 

[Mrmonk7663]

Alright, in case you didn’t see my saga with the cam, I am happy to report that it has been fixed via belt sanding. Clearance is now fine for the engine and it should be good to go.

I also got word today that my head has been finished. I’ll pay the invoice tomorrow and wait for it to arrive.

Details on head:
Non Hemi Head
Milled .030
Ported
22lb springs
Valve seats checked and trued
Valves lapped in for perfect seating
.027 MLS Head Gasket

Piston sits .004 in the block which will give me .031 clearance...more than enough.

It should compliment the engine mods and Mikuni great and make some nice power.

Ordered some front 6” wheels today with 15x6 knobby tires.
Ordered 8x8.5 rear wheels.
Need to order rear tires. I believe I have settled in 18” tears. With a torque converter and 6.75:1 gearing that combination should work great for the Baja’s intended purpose.

I believe the only other things I need are brake cables, throttle cables, twist throttle, brake levers, and 2 4” bands/drums.

More updates to come next week when the PC Is done and the head arrives.

 

[Dingocat]

Pc? Building one?

Nvm powdercoat lol

 

[Mrmonk7663]

Been a while since I built a PC haha.

 

[Mrmonk7663]

The cylinder head arrived today. 22lb springs, ported and polished exhaust polished only), milled .030. I’ll install it later this week with some new headstuds and the .027 headgasket. Still waiting for the frame to come back from coating. More to come...

 

[Mrmonk7663]

After some thinking I believe that instead of 18” rear tires 16” will work better. The 16” will allow me to use a 9t jackshaft sprocket in conjunction with the 54t axle sprocket. With 18” I would need an 8t jackshaft and it’s just so dang thin. 16” is an odd size for 8” wheels, but is very popular for 7” wheels. I should get the Baja back this week from PC.